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<p>Copper/nickel bimetallic structures, which combine high thermal conductivity and mechanical strength, are increasingly employed in aerospace applications, particularly in liquid rocket thrust chambers featuring high-conductivity copper inner linings and high-strength nickel-based outer walls. Laser-based Directed Energy Deposition (DED-LB) is a promising technique for fabricating such Cu/Ni bimetallic structures; however, further research on interfacial gradient process optimization is required. This study investigates the process parameters and microstructure evolution in DED-LB Inconel 718 (In718) on CuCr0.8 high-copper alloy substrates. The mechanical and thermal expansion properties of both CuCr0.8 and In718 were evaluated. Optimized process windows were determined as 1600–2000 W for the first layer, 800–1200 W for the second layer, and 400–1200 W for subsequent layers. A gradual elemental transition was observed at the interface, contributing to the formation of a strong metallurgical bond. The tensile strength of the In718 layer was 903.67 ± 18.23 MPa, significantly higher than the 259.98 ± 1.21 MPa of CuCr0.8. At 100 °C and 200 °C, the coefficients of thermal expansion (CTE) for CuCr0.8 and In718 were comparable; however, at 300&#xa0;°C, CuCr0.8 showed a markedly higher CTE. These findings offer valuable insights for the design and additive manufacturing of high-performance bimetallic components in liquid rocket engines, advancing the development of next-generation aerospace technologies.</p>

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Process optimization and characterization of Inconel718 coatings on high copper alloys by laser-based directed energy deposition

  • 期刊论文

  • 发表日期：

    2025年6月14日

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  • Baopeng Zhang,
  • Haifeng Xiao,
  • Zhanxiang Gao,
  • Yunpeng Li,
  • Wenqi Zhang,
  • Guangxuan Zhou,
  • Haihong Zhu

摘要

Copper/nickel bimetallic structures, which combine high thermal conductivity and mechanical strength, are increasingly employed in aerospace applications, particularly in liquid rocket thrust chambers featuring high-conductivity copper inner linings and high-strength nickel-based outer walls. Laser-based Directed Energy Deposition (DED-LB) is a promising technique for fabricating such Cu/Ni bimetallic structures; however, further research on interfacial gradient process optimization is required. This study investigates the process parameters and microstructure evolution in DED-LB Inconel 718 (In718) on CuCr0.8 high-copper alloy substrates. The mechanical and thermal expansion properties of both CuCr0.8 and In718 were evaluated. Optimized process windows were determined as 1600–2000 W for the first layer, 800–1200 W for the second layer, and 400–1200 W for subsequent layers. A gradual elemental transition was observed at the interface, contributing to the formation of a strong metallurgical bond. The tensile strength of the In718 layer was 903.67 ± 18.23 MPa, significantly higher than the 259.98 ± 1.21 MPa of CuCr0.8. At 100 °C and 200 °C, the coefficients of thermal expansion (CTE) for CuCr0.8 and In718 were comparable; however, at 300 °C, CuCr0.8 showed a markedly higher CTE. These findings offer valuable insights for the design and additive manufacturing of high-performance bimetallic components in liquid rocket engines, advancing the development of next-generation aerospace technologies.