EWI’s Laser Equipment

15-kW IPG Fiber Laser

4-way beam switch

15-kW Laser

Laser Optics for Broad Coverage

Off-the-shelf integrated focusing optic Integrator lens with 6- × 8-mm rectangular spot

Beam shape on thermoplastic burn block

Beam shape on burn paper

Integrator Lens

Broad Process Setup

Fiber optic delivery

Laser head

Integrator lens

Custom power nozzle Powder

delivery line

Powder delivery system

Samples

Stainless to Steel

Stellite to Steel

Inconel(2 pass)

Dilution

6 mm

L1

L2

A3A2A1

~2.6% Dilution

Dilution typically less than 5%

10-kW Fiber Laser

316L on 4130 9- × 12-mm rectangular spot 8 kW ~1 mm build-up (single pass)

Submerged Arc Strip Cladding SASC

Typically 750 A, up to 40 lb/hr Typical dilution of 10-20%

Electroslag Strip Cladding

ESC - Typically 1400 A, up to 60 lb/hr, dilution 5-15%

Additive Manufacturing (AM) – An Extension of Cladding From single beads

stacked upon each other (bottom)

To large features at high deposition rates (top)

Mitigated by balance of net-shape, metallurgical requirements, mechanical properties (tensile, fatigue, etc.)

AM – Progressive Layers

Additive manufacturing - build in layers, stress relieve/PWHT, machine, as/if necessary

Deposition Rate vs ResolutionCourtesy Boeing

Decreased Resolution

Incr

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sed

De

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sitio

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ate

Summary

Surface engineering is a broad field ranging from ion implantation to explosive cladding in terms of the mass of material deposited in unit time.

Practical methods for powder and strip cladding areas large and small, across a range of industries, include fusion-based processes such as GTA, PTA, GMA, laser, SASC, and ESSC depending on the area to be clad, deposit thickness, and chemistry required. Others include thermal spray, e.g., HVOF.

Many processes require two layers to achieve the desired surface chemistry and corrosion resistance; others require only one layer.

Questions?Ian D. HarrisTechnology Leader, Arc WeldingEmail: iharris@ewi.orgPhone: 614.688.5131