Surface and Interface Characteristics of an Electrodeposited Ni-Layer on Additively Manufactured Inconel-718 Alloy

The present study explores the effect of an electrodeposited nickel layer on Inconel-718 alloy produced using different additive manufacturing (AM) routes, like Laser Powder Bed Fusion (L-PBF), Electron Beam Powder Bed Fusion (EB-PBF), and Laser-Directed Energy Deposition (L-DED). Comparative analyses were conducted by characterizing the physical, mechanical, and surface properties of Ni-coated AM-built Inconel-718 alloy surfaces. Different microstructures of Ni coatings were observed for different AM-built surfaces of Inconel-718 alloy. Influence on the Ni-layer hardness was also noted, plausibly as a consequence of variations in the residual stress of coated specimens. The hardness of Ni-coated specimens was not correlated well with the scratch resistance due to the unique natures of the Ni layer interface with the substrate surface, depending upon the AM route adopted to produce the Inconel-718 alloy builds. A comprehensive analysis of the scratch failure in identically coated specimens built using different AM routes has also been discussed.