Material Characterization of Alloy for Aerospace Application: Effect of Laser Power on the Co-axially Deposited T64 Alloy and Cu

In this research work, 10 wt. % Cu was deposited with 90 wt. % T64 alloy via the laser system. The deposition was performed on an ytterbium laser system with a maximum operating power of 3 kW. The effect of laser power on the laser-deposited T64 + 10 wt. % Cu was investigated. Microstructural analysis and microhardness profiling of the deposited samples were examined. Basket-weave-like Widmanstätten structures were observed in the heat-affected zone of the deposit, and these occur as a result of the cooling rate; however, it increases as the laser power was increased. The average microhardness values were obtained and sample 1 deposited at the laser power of 1000 Watts had the lowest hardness value of HV 309 ± 7, while the highest hardness value of HV 573 ± 7 was obtained for sample 4 deposited at the laser power of 1600 watts. Response surface methodology (RSM) was also implemented using the Design-Expert 11 software to determine the optimum and desirable parameters. The properties of the T64 alloy were improved with the addition of 10 wt.% Cu, and this can be recommended for the engine block of an aerospace application to serve as fire resistant.