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Microstructure-controlled corrosion in directed energy deposited Ni-based superalloy: A review

Mahendra Singh, Ajay Biswas · Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering · 2026

Nickel-based superalloy Inconel 718 is widely used in aerospace, marine, and energy sectors owing to its exceptional high-temperature strength, creep resistance, and corrosion performance. However, conventional manufacturing routes suffer from long lead times, high costs, and geometric limitations for complex components. Directed energy deposition (DED) variants, including the emerging submerged arc DED (SA-DED) process, offer high deposition rates and near-net-shape capability. This review synthesizes recent advances in the development, microstructural evolution, post-processing, and corrosion behavior of Inconel 718 (and closely related Inconel 625) produced by arc-based and laser-based DED. Key findings highlight that as-built deposits exhibit coarse columnar grains, pronounced Nb-rich Laves phase networks, strong {001}⟨100⟩ texture, and micro-galvanic couples that degrade corrosion resistance in chloride environments. Effective mitigation strategies include inoculant addition (ZrO 2 , TiB 2 , Ti 2 AlC, Re), oscillating-arc deposition, inte

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