SUMMARY

Hybrid manufacturing is a combination of additive (deposition) and subtractive (machining)
manufacturing in a single machine tool. This laser metal deposition process can be used for near net
shape manufacturing and component repair using either similar or dissimilar materials. With
commercially available hybrid manufacturing systems capable of 5-axis deposition and subtraction, it is
now feasible to control the interfacial conditions between substrate and deposition. Other deposition
processes require substrates to be planar, but hybrid manufacturing subtractive capability allows for
unlimited surface structures and conditions. Industry implementation has already occurred in the mold
and die repair industry, but it will quickly expand to other applications. This proposed dissertation will
evaluate the use of various material and structure combinations to enhance the mechanical properties
associated with hybrid manufactured components.