Interface Analysis between Inconel 625 and Cobalt-Chromium Alloy Fabricated by Powder Bed Fusion Using Pulsed Wave Laser

A few components used in the aerospace and petrochemical industries serve in corrosive environments at high temperatures. Corrosion-resistant metals or unique processes, such as coating and fusion welding, are required to improve the performance of the parts. We have used laser powder bed fusion (LPBF) technology to deposit a 5 mm thick corrosion-resistant CoCrMo layer on a high-strength IN625 substrate to improve the corrosion resistance of the core parts of a valve. This study found that when the laser volumetric energy density (E(V)) ≤ 20, the tensile strength increases linearly with the increase in E(V), and the slope of the curve is approximately 85°. The larger the slope, the greater the impact of E(V) on the intensity. When E(V) > 20, the sample strength reaches the maximum tensile strength. When the E(V) increases from 0 to 20, the fracture position of the sample shifts from CoCrMo to IN625. When E(V) ≤ 38, the strain increases linearly with the increase in E(V), and the slope of the curve is approximately 67.5°. The sample strain rate reaches the maximum when E(V) > 38. Therefore, for an optimal sample strength and strain, E(V) should be greater than 38. This study provides theoretical and technical support for the manufacturing of corrosion-resistant dissimilar metal parts using LPBF technology.