Thermo-mechanical characteristics of inconel 718 layer deposited on AISI 1045 steel substrate using a directed energy deposition process

The heat treatment and the shape of the substrate greatly affect thermal and mechanical characteristics of the super-alloy-deposited region by a directed energy deposition (DED) process. The goal of this paper is to investigate the influence of the hardness and the slope of AISI 1045 steel substrate on thermo-mechanical characteristics of Inconel 718-deposited region using DED processes to improve the reliability of the fabricated part. The effects of the hardness and the slope on the formation of the fused region, the hardness of the fused region and the residual stress evolution in the vicinity of the deposited region are examined via experiments and thermo-mechanical analyses. In addition, the influence of the hardness and the slope on failure and impact characteristics in the vicinity of the deposited region is investigated. Finally, an effective design of the substrate considering the initial hardness and the slope is proposed.