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Tailored melt pool shape by dual laser beam LMD-w process

Presentation held at MSE, Additive Manufacturing Technologies, September 25th, 2020
: Gipperich, Marius; Riepe, Jan; Day, Robin; Bergs, Thomas

Präsentation urn:nbn:de:0011-n-6351918 (2.2 MByte PDF)
MD5 Fingerprint: 881cb2a389fb418d8e2a9648ce104ee7
Erstellt am: 27.5.2021

2020, 19 Folien
Materials Science and Engineering Congress (MSE) <2020, Online>
Deutsche Forschungsgemeinschaft DFG
Grundlagenuntersuchungen zur Erweiterung des Verständnisses eines 2-Strahl-Laserprozesses für metallische Werkstoffe
Vortrag, Elektronische Publikation
Fraunhofer IPT ()
Laserauftragschweißen; LMD-W; laser metal deposition; modulated laser beam; melt pool shape; temperature control

Additive Manufacturing (AM) is a fast growing manufacturing market. Laser Metal Deposition (LMD) is a high deposition rate metal AM process mostly used for repair, cladding or manufacturing applications. The two commonly used LMD-processes are powder-based (LMD-p) and wire-based (LMD-w). While LMD-p offers high deposition rates up to 2 kg/h (compared to LMD-w with 1kg/h) the handling of powder in terms of health and safety as well as machine wear become important. Furthermore, the material efficiency (due to overspray) is lower compared to the LMD-w AM-process. This is where LMD-w offers advantages, but advanced concepts to improve the stability of the LMD-w process to the level of LMD-p are needed. In this presentation, an approach is investigated to stabilize the LMD-w process by combining continuous wave (cw) laser and low-power pulsed wave (pw) laser. Calorimeter-like absorption measurements as well as deposition experiments are carried out to understand the physical background of the dual laser process and how this setup helps to stabilize the process. Promising results were achieved showing the possibility to tailor the melt pool height and width by a factor of 1.5-2 and an increase of energy absorption by 20%. This leads to a new perspective for the LMD-w manufacturing process (3D part build up, cladding and repair) in many industry sectors such as mobility, energy and engineering.