Laser Cladding
-
Upload
habeebmohammedfarooq -
Category
Documents
-
view
331 -
download
5
description
Transcript of Laser Cladding
CLADDING AND ADDITIVE MANUFACTURING USING LASER APPLIED POWDER® PROCESSES
CLADDING AND ADDITIVE MANUFACTURING USING LASER APPLIED POWDER® PROCESSES
AWS New Welding TechnologiesAWS New Welding Technologies
June 15 -16, 2010June 15 -16, 2010
Salay StannardSalay Stannard
AWS New Welding TechnologiesAWS New Welding Technologies
June 15 -16, 2010June 15 -16, 2010
Salay StannardSalay Stannard
Who Is Joining Who Is Joining Technologies?Technologies?
• About 60 employees• 25,000 SF, With Room to Expand At Current Location
• 2,000 SF Dedicated to Laser Cladding• Laser Applied Wire (LAW®) Additive Processing• Laser Applied Powder (LAP®) Additive Processing
• Laser Welding• EB Welding• GTAW• Lasers Systems Design & Integration• Supply Chain Management• ISO 9001:2000 • AS9100• NADCAP Certified for Welding
The Necessity for Component The Necessity for Component Repair and Surfacing Repair and Surfacing TechnologiesTechnologiesWhy repair technologies are needed:
• Wear and Damage• Sealing Surfaces• Mounting / Fretting Surfaces• Bearing and Loaded Surfaces• Tools and Dies
• Manufacturing Nonconformities• Under filled castings• Incorrect Machining• Design Changes
• High Value Parts• Long Lead Times
Laser Based Repair TechnologiesLaser Based Repair Technologies
• Pulsed Wire Cladding
• CW Laser Wire Cladding
• Laser Blown Powder
Cladding
Pulsed Laser Wire CladdingPulsed Laser Wire Cladding• Wire is positioned on top of substrate• Wire is stationary relative to part• Laser fuses wire to substrate by a
series of spot welds• Manual or automated processing• Manual process is well suited to
limited production or highly irregular repairs
• Not well suited to crack sensitive materials due to rapid heating and cooling rates
• Low deposition rates due to low average laser power, limited pulse rate and need to synchronize wire and part feed
Continuous Wave (CW) Laser Wire Continuous Wave (CW) Laser Wire CladdingCladding• Laser beam creates molten pool
on part• Filler wire is fed into pool by
precision wire feed• Wire is melted and incorporated
into the pool to create a bead• Process is nearly always
automated• Better for crack sensitive
materials• ~10x higher deposition rates than
pulsed wire
Laser Powder CladdingLaser Powder Cladding• Laser beam creates molten pool on
part• Metal powder is blown into pool
by precision powder feed system• Powder is melted and
incorporated into the pool to create a bead
• Process is always automated• Largest selection of available clad
materials• ~10x higher deposition rates than
CW wire feeding
Blown Powder Nozzle Schematic Multijet Nozzle Coaxial Nozzle
Laser Powder CladdingLaser Powder Cladding
Need for Cladding and Additive Need for Cladding and Additive ManufactureManufacture
• Aerospace
• Power Generation
• Oil/Gas
Special Challenges in Aerospace Special Challenges in Aerospace ProcessingProcessing
• Process: Limited industry specificationsFAA & OEM barriers
• Limited to repair and design workDocument/ControlStringent metallurgical requirements
Minimal heat input requiredPoor capture rate: 30-40% detail, 12-20% knife edges
• Machine cannot be modified after source approval
• Test pieces are rare due to high cost of part
Need: Overhaul and Repair
Special Challenges in Power GenerationSpecial Challenges in Power Generation
• Longer processing times for large part surface areas
JT: 9.6lb/hr approx 90% capture
• Part geometry varies job to job
• Less stringent on powder quality
• Open metallurgy requirements Accepting of ↑HAZ, dilution, etc.
Need: Hard facing, corrosion resistance
Special Challenges in Oil/GasSpecial Challenges in Oil/Gas
• Longer processing times for large part surface areas
• Less stringent on powder quality
• Accepting of ↑HAZ, dilution, etc.
Need: Hard facing, corrosion resistance,
wear resistance
Work Cell for Aerospace ProcessingWork Cell for Aerospace ProcessingPlatform:
• Cartesian CNC preferred• Beam quality is importantSolid-state systems -Disk or fibre lasersJT: 2kW → 4kW Trumpf disk laser
Clad Requirements:• Powder- Rotary vs. Atomized
Quality is critical!• Accepting of additive with wire• Typical repair thickness < 0.060”
Materials deposited include:• Stellite 6, 21• SS410, 410L• IN 100
• Inconel 625, 718• 4047
Work Cell for Power Generation Work Cell for Power Generation ProcessingProcessingPlatform:
• Flexible beam quality, direct diode systems possible
• 3 -7mm spot size • Coaxial system, He powder delivery
Clad requirements:
• Typical thickness 0.040” – 0.200” JT: deposited 0.040” – 3+”• 30-60 HRc, > 45 HRc cracking possible with carbide
powders
Materials deposited include:• Inconel 622, 625, 718• Carbides
• Stellite 6, 21• Ni-Cr
• Tool Steels
Work Cell for Oil/Gas ProcessingWork Cell for Oil/Gas ProcessingPlatform:
• Flexible beam quality, direct diode systems possible
• 3 -7mm spot size • Coaxial system, He powder delivery
Clad requirements:
• Typical thicknesses 0.040” – 2”• > 0.080” cracking possible
Materials deposited include:• Carbides• Ni-Cr• Inconel 622, 625, 718• Stellite 6, 21
• WC-Cr• WC-Co-Cr
Advantages of Powder vs. WireAdvantages of Powder vs. WireLaser Wire Cladding
• Welding with wire is a well established aerospace process
• Typically lower capital investment than for powder• Crack and pore free deposition is attainable for many
common aerospace materials using commercially available wire
• 100% utilization of filler material
Laser Powder Cladding:• Higher maximum deposition rates• Larger variety of possible clad materials• Processing head is compact, omnidirectional and
completely non contact• Minimum feature size and heat input are limited only
by minimum laser focus size and economics• Lower dilution
LAW ® Work Cell Equipment• Designed and built by Joining Technologies
• Trumpf TruDisk 1000 Laser supply
• 3- Axis CNC control with rotary
• Wire 0.010” – 0.025” diameter
• Closed loop servo controlled wire feed
• Real time power density control while welding
• Non contact profile scanning with data storage
• Highly efficient wire placement algorithms
• Vision based wire tracking within 0.003”
• Real time work piece temperature control
• Trumpf TruDisk 4002 (4kW) Laser Supply
• KUKA KR 30/HA (High Accuracy) Robot
Approx. 6ft radius hemisphere range
66lbs. payload
• KUKA DKP 400.1 Rotary/Tilt Table
Approx. 880lbs. load
• Programmable Dual Powder Feeders
• On the Fly Focus spot size control
• Multi-jet or Coaxial powder delivery
LAP ® Work Cell Equipment
Equipment Acquisition• August installation of Trumpf 505 Powder Cladding system
• 6kW CO2 Laser
• 6.5ft X 3.2ft X 2.5ft envelope
• 5 Axis motion platform
• High capacity rotary
• Programmable spot size
• High absolute and relative accuracy
• Two hopper powder feed
Lab Expansion and LAP ® Upgrade• Additional 10,000 sq ft cladding workspace
• Accommodations for parts up to
3ft dia x 40ft long x 5 tons
• 30ft linear rail for robot positioning
• Multi-ton capacity precision head stock,
tail stock and steady rests
• Both laser additive technologies, wire and powder, have many overhaul and repair applications for the aerospace, power generation, and oil/gas industries.
• When compared to traditional repair processes additive manufacturing maintains base metallurgy with low heat inputs and a high degree of control.
• Industry acceptance remains a challenge, but is sure to improve with continued research, development and testing.
Salay Stannard Process Development Engineer [email protected] Poeppel Manager of Additive Processes [email protected] Hudson President [email protected]
Visit www.joiningtech.comfor a detailed list of capabilities and to sign up for our industry video blog