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 salays@joiningtech.comScott Poeppel Manager of Additive Processes spoeppel@joiningtech.comDave Hudson President dhudson@joiningtech.com

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