Direct manufacturing of net-shape functional components by laser consolidation process (invited paper)

Laser consolidation (LC) is a novel computer-aided manufacturing process developed by the Industrial Materials Institute of National Research Council of Canada (NRC-IMI). This rapid manufacturing process produces net-shape functional metallic parts layer-by-layer directly from a computer aided design (CAD) model by using a laser beam to melt the injected powder and re-solidifying it on the substrate or previous layer. As an alternative to the conventional machining process,this novel manufacturing process builds net-shape functional parts or features on an existing part by adding instead of removing material. In this review paper,LC of CPM-9V tool steel,Ni-based IN-625 and IN-718 superalloys,and Ti-6Al-4V alloy will be discussed. The microstructures and functional properties of these laser consolidated materials will be examined along with several potential industrial applications.