High-performance laser cladding with combined energy sources

Research output: Contribution to journalResearch articleContributedpeer-review

Contributors

  • Steffen Nowotny - , Fraunhofer Institute for Material and Beam Technology (Author)
  • Frank Brueckner - , Fraunhofer Institute for Material and Beam Technology (Author)
  • Sebastian Thieme - , Department of Paediatrics, Fraunhofer Institute for Material and Beam Technology (Author)
  • Christoph Leyens - , Chair of Materials Technology, Fraunhofer Institute for Material and Beam Technology, TUD Dresden University of Technology (Author)
  • Eckhard Beyer - , Chair of Laser and Surface Technology, Fraunhofer Institute for Material and Beam Technology, TUD Dresden University of Technology (Author)

Abstract

In the field of laser additive manufacturing, modern hybrid technologies offer advantageous solutions for combining the high quality level of laser surface claddings with the industry's economical requirements regarding productivity and energy efficiency. The technical approach is to supply energy sources in two fundamentally different ways. First, welding material in the form of wire is directly heated, i.e., by electrical resistance, almost to its melting point and is fed to the process region simultaneously with the laser beam. A newly developed coaxial wire head allows for omni-directional welding operation and, thus, the use of wire even for complex surface claddings as well as layer-by-layer fabrication of metallic parts. Second, an additional energy source is used to heat the substrate in order to compensate for the heat conduction losses. This technical variant is suitable for use with both wire and powder as deposition materials. Additionally, heating and cooling gradients can be precisely adjusted, thus improving the build-up of structures of hard and brittle metallic super-alloys. Currently, deposition rates up to 18-kg/h of metal alloys and metal matrix composites have been demonstrated using these laser hybrid techniques. Industrial applications are, among others, large hydraulic cylinders and tools of the oil and mining industries.

Details

Original languageEnglish
Article numberS17001
JournalJournal of laser applications
Volume27
Issue numberS1
Publication statusPublished - 1 Feb 2015
Peer-reviewedYes

Keywords

Sustainable Development Goals

Keywords

  • additive manufacturing, coaxial laser head, hybrid technology, laser cladding