Laser Cladding (LC) Inconel 718 Superalloy 3D Printed Turbo Charger With CNC Machining
Introduction to Laser Cladding and CNC Machining of Inconel 718 Turbocharger Parts
Laser Cladding (LC), a form of Directed Energy Deposition (DED), is used to build or repair Inconel 718 turbocharger components with high thermal fatigue and wear resistance. This technique is ideal for extending service life or building near-net shape high-performance parts.
At Neway Aerotech, we combine Inconel 718 additive manufacturing with precision CNC machining to produce finished turbocharger housings, volutes, and impellers with tight dimensional control and extreme temperature durability.
Laser Cladding Technology for Inconel 718 Turbo Parts
LC Process Parameters and Benefits
Parameter | Value | Description |
|---|---|---|
Cladding Layer Height | 0.3–1.0 mm | Controlled buildup per layer |
Deposition Rate | 5–20 cm³/min | Fast processing for medium-to-large parts |
Laser Power | 1–3 kW | Tuned based on dilution zone and feature size |
Shielding Gas | Argon (>99.99%) | Ensures clean melt pool and interface bonding |
Typical Build Area | Up to 600 × 600 × 500 mm | Supports turbine housings, flanges, scroll walls |
Laser cladding ensures metallurgical bonding to the substrate, ideal for both repair and additive fabrication of Inconel 718 components.
Inconel 718 Performance Advantages in Turbochargers
Property | Value | Role in Turbo Applications |
|---|---|---|
Yield Strength @ 700°C | ≥ 720 MPa | Structural stability under hot-gas flow |
Fatigue Life | >10⁸ cycles @ 650 MPa | Resistance to vibration and thermal cycling |
Oxidation Resistance | Up to 980°C | Withstands exhaust exposure and high boost heat |
Thermal Expansion Coefficient | 13 µm/m·°C | Maintains interface geometry during temperature shifts |
Creep Resistance | >1000 h @ 704°C | Sustained loading in high RPM operation |
CNC Machining Post-Processing Strategy
After cladding or near-net laser deposition, components are finish-machined to final geometry and tolerance.
Machining Features: Flange faces, mounting bosses, scroll inlets/outlets, turbine bores.
Tolerances Achieved: ±0.01 mm on sealing faces; <0.02 mm bore concentricity.
Tooling Strategy: CBN or ceramic inserts for hardened Inconel surface; high-pressure coolant recommended.
CNC Services: Multi-axis finishing ensures precision fit with turbine core assemblies.
Case Study: Inconel 718 Turbocharger Scroll Rebuild via Laser Cladding and CNC Finishing
Project Background
A commercial turbocharger from a marine gas engine exhibited wall thinning and erosion in the scroll area. The client required restoration with performance equal to a new housing at reduced cost and lead time.
Manufacturing Workflow
Material Base: Inconel 718 forged housing with damage in inner volute and gas inlet area.
Preparation: Worn area machined to uniform cavity; preheating to 200°C for stress mitigation.
Laser Cladding: Inconel 718 powder, 45–105 μm, deposited at 12 cm³/min with 2.2 kW fiber laser.
Interpass Temp: Maintained at 250–300°C; total 6 layers, final wall built to 8 mm thickness.
Post-Clad Heat Treatment: HIP at 1180°C / 100 MPa, followed by aging at 720°C for 8 h + 620°C for 8 h.
CNC Finishing: Bore restored to ±0.015 mm, face milled, and flanges re-drilled.
Inspection & Validation
CMM inspection confirmed alignment within spec.
X-ray showed no bonding or internal defects.
Ultrasonic Testing validated density across rebuilt region.
Flow simulation passed at 1850 L/min, with <2% pressure drop variance from new OEM part.
Results and Verification
The rebuilt turbocharger scroll exceeded expectations in pressure, thermal, and flow performance. Mechanical testing confirmed yield strength ≥720 MPa and microhardness 340 HV. The component completed 1200-hour bench endurance at 940°C with no fatigue or wear failure.
FAQs
What is the maximum wall thickness buildable using laser cladding for Inconel 718?
Can Inconel turbo parts be repaired using LC instead of full replacement?
How is CNC tolerance managed after laser deposition on superalloys?
What heat treatment is required after LC on Inconel 718?
Do LC-restored turbo parts meet OEM gas flow and pressure specs?
