The present study was focused on the assessment of microstructural anisotropy of IN 625 manufactured by selective laser melting (SLM) and its influence on the material’s room temperature tensile properties. Microstructural anisotropy was assessed based on computational and experimental investigations. Tensile specimens were manufactured using four building orientations (along Z, X, Y-axis, and tilted at 45° in the XZ plane) and three different scanning strategies (90°, 67°, and 45°). The simulation of microstructure development in specimens built along the Z-axis, applying all three scanning strategies, showed that the as-built microstructure is strongly textured and is influenced by the scanning strategy. The 45° scanning strategy induced the highest microstructural texture from all scanning strategies used. The monotonic tensile test results highlighted that the material exhibits significant anisotropic properties, depending on both the specimen orientation and the scanning strategy. Regardless of the scanning strategy used, the lowest mechanical performances of IN 625, in terms of strength values, were recorded for specimens built in the vertical position, as compared with all the other orientations.

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Laser defocusing was investigated to assess the influence on the surface quality, melt pool shape, tensile properties, and densification of selective laser melted (SLMed) IN 625. Negative (−0.5 mm, −0.3 mm), positive (+0.3 mm, +0.5 mm), and 0 mm defocusing distances were used to produce specimens, while the other process parameters remained unchanged. The scanning electron microscopy (SEM) images of the melt pools generated by different defocusing amounts were used to assess the influence on the morphology and melt pool size. The mechanical properties were evaluated by tensile testing, and the bulk density of the parts was measured by Archimedes’ method. It was observed that the melt pool morphology and melting mode are directly related to the defocusing distances. The melting height increases while the melting depth decreases from positive to negative defocusing. The use of negative defocusing distances generates the conduction melting mode of the SLMed IN 625, and the alloy (as-built) has the maximum density and ultimate tensile strength. Conversely, the use of positive distances generates keyhole mode melting accompanied by a decrease of density and mechanical strength due to the increase in porosity and is therefore not suitable for the SLM process.

The main drawbacks of the Laser Powder Bed Fusion (LPBF) process are the surface quality and dimensional accuracy of manufactured parts due to the edge and corner effects. These effects can be diminished by using an appropriate balance of the process parameters and scanning strategies. This paper focuses on the assessment of reducing the edge and corner effects that occur in additively manufactured IN 625 alloy via the LPBF technique by varying the hatch angle rotation (by 45°, 67°, and 90°) and volumetric energy density (VED), and using the laser top surface remelting technique (LSR). The edge and corner effects of the cubic samples were quantitatively evaluated on the top surface by 3D laser surface scanning. It was found that the edge and corner effects became more pronounced in the cases of samples built with no contour and hatch angles of 45° and 67°, while the smallest deformations were obtained when the hatch angle was rotated by 90°. Moreover, the heights of both the edge and corner ridges increase as the number of remeltings passing the top layer increases. Conversely, when a lower VED was used for melting the top layer(s) of the samples, the edge and corner ridges were slightly reduced.

The high-temperature oxidation behavior of selective laser melting (SLM) manufactured IN 625 was studied over 96 h of exposure at 900 °C and 1050 °C in air. An extensive analysis was performed to characterize the oxide scale formed and its evolution during the 96 h, including mass gain analysis, EDS, XRD, and morphological analysis of the oxide scale. The mass gain rate of the bare material increases rapidly during the first 8 h of temperature holding and diminishes at higher holding periods for both oxidation temperatures. High-temperature exposure for short periods (24 h) follows a parabolic law and promotes the precipitation of δ phase, Ni-rich intermetallics, and carbides. Within the first 24 h of exposure at 900 °C, a Cr2O3 and a (Ni, Fe)Cr2O4 spinel scale were formed, while at a higher temperature, a more complex oxide was registered, consisting of (Ni, Fe)Cr2O4, Cr2O3, and rutile-type oxides. Prolonged exposure of IN 625 at 900 °C induces the preservation of the Cr2O3 scale and the dissolution of carbides. Other phases and intermetallics, such as γ, δ phases, and MoNi4 are still present. The exposure for 96 h at 1050 °C led to the dissolution of all intermetallics, while the same complex oxide scale was formed.

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Additive manufacturing of high-quality materials by Selective Laser Melting depends not only on establishing appropriate process parameters, but also on the characteristics of the metal powders used and their stability over time or after recycling. The aim of the research was to characterize the IN 625 powder used over multiple manufacturing cycles with a Lasertec 30 SLM machine. In order to achieve the research's goal, virgin and recirculated powder's physical and technological characteristics were investigated. A decrease in all D-values (D10, D50, D90) of the powder size distribution was observed after multiple recirculation cycles showing a decrease of the powder dimensional range over time. Both virgin and recirculated powders are composed of mainly spherical particles, but elongated particles and satellite particles were observed as well. The dimensional evolution analysis showed a deviation from the powder ideal roundness, deviation that is more pronounced over multiple recirculation cycles. It was experimentally determined that the powders present a good flowability based on the flow rate value obtained for both virgin and recirculated powders, confirmed also by the Hausner ratio and angle of repose.

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