Hybrid additive-subtractive manufacturing for aerospace metal components is an emerging approach that integrates the design flexibility of additive processes with the precision of machining. However, ..
Hybrid additive-subtractive manufacturing for aerospace metal components is an emerging approach that integrates the design flexibility of additive processes with the precision of machining. However, the effect of dwell-time modulation and machining control on the geometric performance of Cr₃C₂-NiCr-reinforced stainless steel (SS 316L) parts has not been systematically explored. This study investigates three dwell-time strategies to enhance the dimensional accuracy of laser-based directed energy deposition (L-DED) builds prior to subtractive finishing. Using a Flex Series Hybrid Manufacturing system with interchangeable toolheads, three samples were fabricated under static, exponential, and combined exponential-cubic dwell functions. The static dwell (10 s) caused heat accumulation and surface warping, while the exponential function improved dimensional accuracy. The combined exponential-cubic dwell achieved the highest geometric stability in as-built parts. Subsequent CNC milling further enhanced dimensional accuracy and surface finish. These results demonstrate that optimized dwell-time control, coupled with hybrid machining, is a critical parameter for achieving high-quality, geometrically stable ceramic-reinforced metal composites. This work advances process optimization strategies for hybrid manufacturing and contributes to improving the quality of aerospace components.
