Influence of Substrate Preheating on Processing Dynamics and Microstructure of Alloy 718 Produced by Directed Energy Deposition Using a Laser Beam and Wire

Effective thermal management is essential in metal additive manufacturing to ensure process stability and desirable material properties. Directed energy deposition using a laser beam and wire (DED-LB/w) enables the production of large, high-performance components but remains sensitive to adverse thermal effects during multi-layer deposition due to heat accumulation. While prior studies have investigated interlayer temperature control and substrate preheating in DED modalities, including laser-powder and arc-based systems, the influence of substrate preheating in DED-LB/w has not been thoroughly examined. This study employs substrate preheating to simulate heat accumulation and assess its effects on melt pool geometry, wire–melt pool interaction, and the microstructural evolution of Alloy 718. Experimental results demonstrate that increased substrate temperatures lead to a gradual expansion of the melt pool, with a notable transition occurring beyond 400 °C. Microstructural analysis reveals that elevated preheat temperatures promote coarser secondary dendrite arm spacing and the development of wider columnar grains. Moreover, Nb-rich secondary phases, including the Laves phase, exhibit increased size but relatively unchanged area fractions. Observations from electrical conductance measurements and coaxial visual imaging show that preheat temperature significantly affects the process dynamics and microstructural evolution, providing a basis for advanced process control strategies.