This study presents a systematic methodology for producing multi-walled carbon nanotubes (MWCNTs)/Inconel 718 composite powder, especially for the Laser Directed Energy Deposition (LDED) process. This approach integrates mild oxidative functionalization of MWCNTs to reduce agglomerations and High-Energy Ball Milling (HEBM) to enhance dispersion over the Inconel 718 powder. The MWCNTs were functionalized through a two-step chemical treatment: (1) magnetic stirring in a 3:1 H2SO4 and HNO3 solution, using two distinct acid concentrations (3 M and 8 M), followed by (2) an ultrasonic bath in H2O2 solution. Structural defects were characterized using Raman spectroscopy (RS), thermogravimetric analysis (TGA), and transmission electron microscopy (TEM), while X-ray photoelectron spectroscopy (XPS) quantified the amount of oxygen-containing functional groups. Among the six functionalization processes, the treatment condition involving 4 h of magnetic stirring, then 2 h in the sonication bath, emerged as optimal, yielding a relatively high functional group attachment (11.47 %) with lower surface defects and without compromising uniformity in mixing. The FESEM analysis of the functionalized MWCNTs (up to 2 wt%)/Inconel 718 composite powder, collected from the LDED machine bed, confirmed uniform dispersion, validating the functionalization strategy. Although developed for LDED, this strategy is also suitable for MMC production processes that use powder as feedstock.
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