Deposition of Nickel-Based Superalloy Claddings on Low Alloy Structural Steel by Direct Laser Deposition

In this study, direct laser deposition (DLD) of nickel-based superalloy powders (Inconel 625) on structural steel (42CrMo4) was analysed. Cladding layers were produced by varying the main processing conditions: power, scanning speed, feed rate, and preheating. The window established based conditions that assured deposited without significant defects a dilution between 15 30%. Scanning electron microscopy, energy dispersive spectroscopy, backscatter diffraction performed for microstructural characterisation. Vickers hardness test used to analyse mechanical response optimised cladding layers. results highlight influence preheating microstructure responses, particularly in heat-affected zone. Substrate 300 °C has strong effect cladding/substrate interface region, affecting distribution. Preheating also reduced formation deleterious Laves phase altered martensite zone, with substantial decrease hardness.