Laser-based additive manufacturing is inherently associated with extreme, unprecedented, and rapid thermokinetics which impact the microstructural evolution in a built component. Such a unique, near to non-equilibrium microstructure/phase evolution in laser additively manufactured metallic components impact their properties in engineering application. In light of this, the present work investigates the unique microstructural traits as a result of process induced spatial and temporal variation in thermokinetic parameters in laser directed energy deposited CoCrMo biomedical alloy. The influence of such a unique microstructural evolution in laser directed energy deposited CoCrMo on electrochemical response in physiological media was elucidated and compared with a conventionally manufactured, commercially available CoCrMo component. Furthermore, while investigation of the electrochemical response, such a microstructural evolution in laser directed energy deposited CoCrMo led to in-situ surface modification of the built components in physiological media via selective, non-uniform electrochemical etching. Such in-situ surface modification resulted in enhanced biocompatibility in terms of mammalian cell growth, cell-substrate adhesion, blood compatibility, and antibacterial properties indicating improved osteointegration, compared to a conventionally manufactured, commercially available CoCrMo component.

Material utilisation is of importance in the manufacturing industry formaking the most of each material, minimising waste and increasing cost-effectiveness. In this thesis, samples of Waspaloy built with the method of L-DED-P has been analysed in order to investigate how process pa-rameters influence the build quality and geometrical accuracy in as-builtobjects. The samples analysed was built in single rows of one, three,five and fifteen layers. A build process was used in which the sampleswere built with individual combinations of the process parameters laserpower, scanning speed, and powder flow. Each combination of processparameters was used to build one track for each layer height.Analysis included defect analysis with light optical microscopy, andpost-processing with ImageJ for automatic identification, quantification,and collection of measurements. A qualitative analysis was performed andthe sample properties and characteristics was described in terms of theamount of defects, including a descriptive assessment of defect severity.Etched samples revealed a columnar grain structure in samples, which was apparent in builds with at least three layers.The results presented show a difference in build height, quantity andsize of pores, and the presence or absence of other defects such as lack of fusion. Sample 3 which was built with high laser power, slow scan-ning speed, and high powder feed show promising results with one ofthe highest build rates of all samples, combined with a low normalisedpore distribution. The sample experiences partial hardening, with hard-ness values reaching 320 HV, but still promisingly show no sign of crackformation.It is concluded that powder feed relates primarily to the build rateof the samples, and the scanning speed together with the laser power influence the quality of the build, where high laser power and low scanningspeed tends to form well behaving samples with few defects, whilst other combinations increase the risk of defects.

<p dir="ltr">A current engineering challenge is to understand and validate material systems capable of maintaining structural viability under the elevated temperature and environmental conditions of hypersonic flight. One aspect of this challenge is the joining of multiple materials with thermal expansion mismatch, which can lead to residual stress, resulting in debits in component lifetime under in-service loading. The focus of this work is a series of studies focused on a ceramic-metal composite (WC/Cu), a zirconia coating applied to a carboncarbon (C/C) composite, and a silicide (R512E) coating applied to a Nb-based alloy (C103). Each of these material systems are candidates for elevated temperature applications in which dissimilar constituents result in residual stress in the material. Each study leveraged experimental residual strain measurements, with the primary focus on the use of synchrotron X-ray diffraction, in conjunction with representative models, and microscopy to illuminate the active mechanisms in the development and evolution of residual stress in the bulk material. The combination of experimental and modeling predictions provides a framework to inform the viability and lifing of material systems exhibiting dissimilar expansion properties.</p>