Laser Deposition of metals such as titanium, stainless steel, nickel, and cobalt alloys, has found increasing application in repair and rapid manufacturing. With suitable choice and control of process parameters, the solidifying metal can cool at rates of over 1000°C/s, which can result in very fine microstructures. With suitable heat-treatment, these microstructures can result in exceptional material properties. In turn, these properties can be exploited to provide opportunities for repair of components previously deemed “unrepairable,” or allow the rapid manufacture of components that might otherwise not be quickly available. This paper will focus on the processing, defects, microstructure, and properties of laser-deposited materials produced by the Laser Engineered Net Shaping (LENS®) technology. Particular attention will be given to repair and rapid manufacture of Ti-6-4 and Inconel components.

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