Laser Consolidation - A One-Step Manufacturing Process for Making Net-Shaped Functional Aerospace Components

Laser consolidation (LC) is an emerging novel computer-aided manufacturing process that produces net-shaped functional parts layer by layer directly from a CAD model, by using a laser beam to melt the injected powder and re-solidifying it on the previous pass. As an alternative to the conventional machining process, this novel manufacturing process builds parts or features on an existing part by adding instead of removing material. In this paper, functional properties of laser consolidated IN-625, IN-738, Ti-6Al-4V and Al-4047 alloys will be reported. The laser consolidated materials exhibit the mechanical properties comparable to respective wrought materials. The examples of laser consolidation for making net-shaped functional components for aerospace applications will also be reported.