Exploring wire laser metal deposition of 316L stainless steel as a viable solution for combined manufacturing routes

The combined manufacturing approach has the potential to facilitate large-scale manufacturing processes, enable on-site manufacturing, and limit welding and joining processes currently used to create complex and flexible components. Laser Metal Wire Deposition (W-LMD) has emerged as a highly promising technology in the field of additive manufacturing (AM). The use of wire feedstock as a cost-effective and safe alternative to powder ensures optimal productivity and meets the demands of the industry. W-LMD would be employed in combined manufacturing for the repair of existing components or the incorporation of intricate features into existing components, thereby facilitating the integration of additive manufacturing across a range of sectors. Nevertheless, an investigation is necessary to determine whether the inherent AM process-related defect or inhomogeneity affects the performance of the hybrid components in question. This study examines the microstructural and mechanical performance of hybrid W-LMD components in continuous, interrupted, and combined manufacturing scenarios. The results demonstrated that the process development strategy is of vital in the production of fully consolidated components (density > 99.9%) for a stable process, irrespective of the deposition scenarios. The tensile properties varied with the process conditions, emphasizing the importance of considering deposition conditions for heat-sensitive alloys in combined manufacturing. The findings aim to provide valuable insights applicable to the production of real industrial components using W-LMD.