Papers by Keyword: Laser Metal Deposition (LMD)

Abstract: In-situ evaluation of crack generation using acoustic emission (AE) technique as a non-destructive testing method was applied during laser cladding of WC-Co cemented carbide via a multi-beam laser metal deposition (LMD) system. Especially, this study aims to investigate relationships between the laser output and the number of cracks generated in beads of WC-12mass%Co cemented carbide cladded by the LMD system. The number of cracks was evaluated using an AE sensor attached to a substrate. The number of cracks was also evaluated from SEM images of beads. By comparing these results, problems in the both evaluation methods for crack generation in laser cladding were discussed.

Abstract: Inside Direct Energy Deposition (DED) processes is the Laser Metal Deposition (LMD) technology. Industries that can implement this technology approach are from automotive to energy sectors where critical parts suffer due to operation cycles, weather or hazardous environments etc. LMD process can be applied for coating, repair and build near net shape geometries. One of the main problems of LMD applied in the coating or in the repair is the dealing with these different types of geometries, to achieve an adherent and homogeneous coating. The current calculation of toolpaths in LMD software is based on a mathematical algorithm that relies on subtractive processes such as machining. The main drawback of using this type of toolpaths is that in this case they do not take into account the overlap between adjacent machining toolpaths. While for machining this parameter is not relevant, in the LMD process, the overlap between two contiguous laser tracks is a critical point to have an adequate process with the required quality. Talens Systems has developed a new Software, Azala software is able to calculate these strategy toolpaths for advanced repairs and coatings in any type of geometry. Beside taking into account the overlapped between contiguous laser clads, the calculated toolpaths have integrated the main laser process in LMD (laser power, process speed, powder flow). The objective of this work is to validate the Azala software developed using a piece with complex geometry on a laboratory scale. The developed software brings the possibility to automate repair and coating, where the LMD process provides a value-added opportunity to reduce production costs due to the repair of value-added components.

Abstract: Wire-based laser metal deposition enables to manufacture large-scale components with deposition rates significant higher compared to powder-based laser additive manufacturing techniques, which are currently working with deposition rates of only a few hundred gram per hour. However, the wire-based approach requires a significant amount of laser power in the range of several kilowatts instead of only a few hundred watts for powder-based processes. This excessive heat input during laser metal deposition can lead to process instabilities such as a non-uniform material deposition and to a limited processability, respectively. Although, numerous possibilities to monitor temperature evolution during processing exist, there is still a lack of knowledge regarding the relationship between temperature and geometric shape of the deposited structure. Due to changing cooling conditions with increasing distance to the substrate material, producing a wall-like structure results in varying heights of the individual tracks. This presents challenges for the deposition of high wall-like structures and limits the use of constant process parameters. In the present study, the temperature evolution during laser metal deposition of AA5087 using constant process parameters is investigated and a scheme for process parameter adaptions in order to reduce residual stress induced componential distortions is suggested.

Abstract: Up to now, only a limited amount of metallic materials is investigated for laser additive manufacturing (LAM). However, the demand to widen the application possibilities by enlarging the range of materials for LAM is growing fast. By now, titanium and aluminium alloys are in the focus of research. In contrast, magnesium alloys are rarely used in the field of additive manufacturing, although they possess a low density in combination with a high specific strength. Currently, magnesium structures are mainly produced by casting but during the last years, the use of wrought alloys also increased. A reason for the rare use of magnesium alloys for LAM technologies might be the high flammability of magnesium powders. This difficulty can be avoided by using magnesium wire for laser metal deposition (LMD). In the present study, the microstructural characteristics of a LMD processed AZ31 magnesium alloy are investigated. For this purpose, optical microscopy and scanning electron microscopy were used. With the help of EDX and EBSD analysis, a change of the chemical composition and micro texture with structure height was identified. The relationship of microstructure and local mechanical properties was investigated with the help of Vickers micro hardness testing. Based on the obtained results it can be concluded that the microstructural characteristics of laser additive manufactured magnesium alloys differ from those of titanium and aluminium alloys. Thus, a wider application spectrum of LMD and magnesium alloys can be opened up.

Abstract: In this study, LMD-CLAD® process (Direct Laser Additive manufacturing) is developed for alumina and Al₂O₃-Y₂O₃-ZrO₂ ternary eutectic compositions. Powder flowability, laser-material interaction and thermal gradient control have been investigated. Powder granules of aforementioned compositions have been designed by spray-drying. Particle size distribution, Hall funnel test and SEM observations have been performed. Flowability has been improved by 20% in order to match with the LMD-CLAD® process by adjusting their density, size and surface quality. Otherwise, optical absorption of the ceramics has been increased up to 90% thanks to the addition of doping ions. With such a flowability improvement, laser powder deposition tests were successful and enabled us to investigate the effect of laser parameters and thermal environment on deposited beads state.

Abstract: This study aims to investigate the microstructure and hardness of multi-layered Stellite-6/WC metal-matrix composites coatings on metallic substrates cladded by laser metal deposition (LMD) for improvement of wear and corrosion resistances. As coating materials, Stellite-6 and WC-12wt.%Co powders were selected. Powder mixtures having various mixing-ratios of Stellite-6 and WC-12wt.%Co were provided vertically on S45C substrates by controlling powder feeding rates of the two powder feeders, individually. Stellite-6/WC composites which consist of three layers with different compositions were cladded on the S45C substrates by laser melting. Cross-sectional microstructure observation was carried out by using an optical microscope (OM). Vickers microhardness tests were conducted to evaluate hardness of the cladding layers and substrates. The experimental results demonstrate that hard multi-layered Stellite-6/WC metal-matrix composites coatings were successfully cladded on the S45C substrates. Property gradients in the Stellite-6/WC composites could be made due to the position-dependent chemical composition and microstructure made by controlling powder feeding rates of an LMD system.

Abstract: In future, the use of tailored multi material parts consisting of thermoplastics and metals will increase especially in the field of automotive applications based on the pursuit of lightweight design. This provides completely new demands on automated manufacturing because dissimilar materials have to be joined reliably. A promising approach is the thermal joining by laser radiation which enables a non-contact, automated and reproducible production of thermoplastic metal hybrids. Thereby, laser radiation heats the metal and through heat conduction the thermoplastic melts and wets the metal surface. The surface topography of the metallic joining partner plays an important role for the strength of the hybrid joint. In this paper, a novel approach for the fast and flexible fabrication of part-adapted surface structures by means of laser cladding with powder injection is investigated. The aim of the performed experiments is to find out how the geometry and arrangement of additive manufactured line-like metallic structures affect the strength of the dissimilar joint. Therefore, the height and width of the structures are varied. The structure geometries are investigated by microscopy of cross-sections and laser-scanning microscope measurements. As substrate and powder material stainless steel is used. Finally, the metallic samples are joined with polyamide 12 by means of laser radiation and mechanically analyzed by tensile shear tests.

Abstract: TiC reinforced titanium matrix functionally graded materials （FGM） has been produced by processes of laser metal deposition through changing the powder feed rate of Ti and Cr3C2 powder. The OM, SEM, EDS methods were used to analyze the components and microstructure of the coatings. Microhardness and wearing resistance at room temperature of the FGM coating were examined by microhardness tester and wear tester respectively. The results show that FGM coating reinforced by in-situ TiC apparently improved hardness of Ti alloy; the microhardness can reach HV1100, and present gradient distribution along deposition direction. Dry sliding wear properties of these FGM coatings have been compared with substrate materials wearing. The observed wearing mechanisms are summarized and related to detailed microstructural observations. The results show the wear resistance of the coating can be improved by 46.6 times.

Abstract: To increase the strength and erosion resistance of Copper Crystallizer, the system based on Laser Metal Deposition (LMD) process was proposed to clad nickel-based alloy on its surface. With the optimal processing parameters ascertained by large numbers of experiments, the crystallizer was clad nickel-based alloy. The morphology and the microstructures of the cladding layers and bonding interface were analyzed by energy dispersive spectrometer and scanning electronic microscopy. The result shows that the bonding interface realizes the metallurgic and tight bonding.