Hybrid manufacturing systems provide a platform for integrated additive, subtractive and
inspection methods on a single machine setup. The present work explores use of hybrid
manufacturing for hardfacing of performance components for improving wear resistance. In this
work, Stellite-6 was applied to a 410 stainless steel substrate using a hybrid manufacturing system
incorporating multi-axis directed energy deposition and machining. Experimental testing was
conducted to determine the effects of hybrid manufacturing parameters on internal porosity,
surface porosity and microstructure in the cladded material, as well as on the roughness of the final
machined surface. Correlation between porosity measurements made by x-ray tomography and
surface inspection is presented and determination of ideal process parameters for hardfacing of
components using hybrid manufacturing systems is briefly discussed. A deposition process is
presented and implemented on a large industrial component. The component is inspected using
dye-penetrant testing and metallographic techniques.Mechanical Engineerin
