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Laser metal deposition (LMD) is used in industry to coat, additive manufacture, and/or repair high value metal components through deposition and laser induced melting of powder delivered in a gas stream. This study relates to the production of three-dimensional Inconel 625 components by LMD. After LMD, a dense cellular – dendritic structure containing carbides of the type MC, M23C6, and M6C has been detected by x-ray diffraction. Parts with tensile yield strengths, ultimate strengths, and elongations in the range of, respectively, 480–656 MPa, 882–1000 MPa, and 24%–36% have been obtained. Compression testing along and perpendicular to the build direction reveals a slight anisotropy in fracture strength. This is attributed to the preferential orientation of the dendrites parallel to the build direction. Tensile test samples have been fabricated in “lying” and “standing” orientations. The tensile yield and ultimate strength are considerably lower and the elongation is larger for the samples built in standing orientation compared to those built in lying orientation. The tensile properties are affected both by the tensile loading orientation relative to the build orientation and the difference in cooling rate for the two build geometries. The former effect is related to the anisotropic microstructure after LMD. The impact of build geometry on the other hand results in a coarser microstructure and different phase constitution—including larger amount of carbides—in the standing oriented samples due to the lower cooling rate during LMD compared to the lying oriented samples.

Numerous structural health monitoring systems have been investigated extensively in order to enhance safety level and reduce direct operational costs. This work demonstrates the feasibility study of a new concept, the effective structural health monitoring system. The effective structural health monitoring system detects cracks using a system of capillaries incorporated into a structure. The structure with the integrated capillaries is produced by additive manufacturing, a process of adding material layer by layer. The first objective of this study is to prove that the developed system has reached technological readiness level 3. In order to prove that, four-point bending specimens with the integrated effective structural health monitoring system were tested after being produced by additive manufacturing, more specifically by laser metal deposition. The second objective of the study is to indicate that during four-point bending fatigue tests, the integrated structural health monitoring system has no influence on the crack initiation behavior. To do so, the specimens were subjected to the so-called step method. We demonstrate that the effective structural health monitoring has reached technological readiness level 3 and that the presence of effective structural health monitoring did not negatively influence the fatigue initiation process. As higher technology readiness levels are required, further investigations are still in progress.

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