Hybrid manufacturing processes that combine additive and machining operations are gaining relevance in modern industry thanks to the capability of building complex parts with minimum material and, many times, with process time reduction. Besides, as the additive and subtractive operations are carried out in the same machine, without moving the part, dead times are reduced and higher accuracies are achieved. However, it is not clear whether the direct material deposition after the machining operation is possible or intermediate cleaning stages are required because of the possible presence of residual cutting fluids. Therefore, different LMD tests are performed on a part impregnated with cutting fluid, both directly and after the removal of the coolant by techniques such as laser vaporizing and air blasting. The present work studies the influence of the cutting fluid in the LMD process and the quality of the resulting part. Resulting porosity is evaluated and it is concluded that if the part surface is not properly clean after the machining operation, deficient clad quality can be obtained in the subsequent laser additive operation.

The use of the LMD technology as a manufacturing and repairing technique in industrial sectors like the die and mold and aerospace is increasing within the last decades. Research carried out in the field of LMD process situates argon as the most usual inert gas, followed by nitrogen. Some leading companies have started to use helium and argon as carrier and shielding gas, respectively. There is therefore a pressing need to know how the use of different gases may affect the LMD process due to there is a lack of knowledge with regard to gas mixtures. The aim of the present work is to evaluate the influence of a mixture of argon and helium on the LMD process by analyzing single tracks of deposited material. For this purpose, special attention is paid to the melt pool temperature, as well as to the characterization of the deposited clads. The increment of helium concentration in the gases of the LMD processes based on argon will have three effects. The first one is a slightly reduction of the height of the clads. Second, an increase of the temperature of the melt pool. Last, smaller wet angles are obtained for higher helium concentrations.

The present work proposes a novel manufacturing technique based on the combination of Laser Metal Deposition, Laser Beam Machining and Laser Polishing processes for the complete manufacturing of complex parts. Therefore, the complete process is based on the application of a laser heat source both for the building of the preform shape of the part by additive manufacturing and for the finishing operations. Their combination enables to manufacture near-net-shape parts and afterwards, remove the excess material via laser machining, which has resulted to be capable of eliminating the waviness resulting from the additive process. Besides, surface quality is improved via laser polishing to reduce the roughness of the final part. Therefore, conventional machining operations are eliminated, what results in a much cleaner process. In order to validate the capability of this new approach, the dimensional accuracy and surface quality of the resulting parts are evaluated. The process has been validated on an Inconel 718 test part, where a previously additively built up part has been finished by means of laser machining and laser polishing.

Hot stamping dies include cooling channels to treat the formed sheet. The optimum cooling channels of dies & molds should adapt to the shape and surface of the dies, so that a homogeneous temperature distribution and cooling are guaranteed. Nevertheless, cooling ducts are conventionally manufactured by deep drilling, attaining straight channels unable to follow the geometry of the tool. Laser Metal Deposition (LMD) is an additive manufacturing technique capable to fabricate nearly free-form integrated cooling channels and therefore shape the so-called conformal cooling. The present work investigates the design and manufacturing of conformal cooling ducts, which are additively built up on hot work steel and then milled in order to attain the final part. Their mechanical performance and heat transfer capability has been evaluated, both experimentally and by means of thermal simulation. Finally, conformal cooling conduits are evaluated and compared to traditional straight channels. The results show that LMD is a proper technology for the generation of cooling ducts, opening the possibility to produce new geometries on dies & molds and, therefore, new products.

Hybrid machine tools combining additive and subtractive processes have arisen as a solution to the increasing manufacture requirements, boosting the potentials of both technologies, while compensating and minimizing their limitations. Nevertheless, the idea of hybrid machines is relatively new and there is a notable lack of knowledge in the field. Therefore, in the present paper, an insight into the advancements of hybrid machines is given, identifying their real capabilities, together with the latest developments from an industrial context. In addition, the current situation and future perspectives of hybrid machines from the point of view of process planning, monitoring and inspection are discussed. Finally, the challenges that must be overcome and the opportunities that the hybrid machines will provide in the forthcoming years are presented.