Characterization of IN718-Cu Multimaterial Produced by Directed Energy Deposition (DED)

With an emphasis on aerospace applications, this thesis explores the characterisation of copper (Cu) and Inconel 718 (IN718) multimaterial systems created by Directed Energy Deposition (DED). These materials' special combination has exciting possibilities for parts like regeneratively cooled rocket engines, where efficient heat dissipation and excellent mechanical performance are critical. The study investigates the mechanical performance, interface features, and microstructural aspects of IN718-Cu multimaterial samples that were made with different process parameters. In order to eliminate flaws like porosity and lack of fusion and maximize the bonding between the components, preheating and varying overlap percentages during deposition were investigated. Key techniques used are energy dispersive spectroscopy (EDS) for mapping chemical composition, tensile testing to evaluate the mechanical strength of the samples, and porosity investigation using optical microscopy and ImageJ software. The results show that when processed optimally, IN718 and copper offers properties suitable for high-performance aerospace uses.