steve peters, paul denney, mike latessa, & max radke lia ... presentation 17.pdf · power...

Power Supplies for Hot Wire CladdingPower Supplies for Hot Wire Cladding Steve Peters, Paul Denney, Mike Latessa, & Max Radke

LIA Laser Additive Manufacturing 2012 Workshop March 1, 2012

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Presentation OutlinePresentation Outline

• Lincoln Electric: Who are we, why are we interested in Lasers?• Hot power sources, what has changed?• Hot Wire Laser: What applications fit?

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Lincoln Electric CompanyLincoln Electric Company

John C. Lincoln James F. Lincoln

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Lincoln Electric CompanyLincoln Electric Company

40 Manufacturing Facilitiesi 19 C t i

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in 19 Countries

Lincoln Electric CompanyLincoln Electric Company

• Transportation / Automotivep• Process & Power Generation• Offshore• Pipeline• Maintenance & Repair

S S & C• Structural Steel & Construction• Heavy Fabrication• Shipbuilding• Shipbuilding• Pipe Mill

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Lincoln Electric CompanyLincoln Electric CompanyConsumables Equipment

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Lincoln Electric CompanyLincoln Electric CompanyConsumables Equipment

Core Competency: Metal Cutting, Welding, and Additive

• Cutting

• Autogenous

• Hybrid Laser Arc

• Hot Wire Laser

Why Lasers?

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y

Lincoln Electric’s Activities in Laser Processing

• Teamed with IPG Photonics– World leader in fiber lasers

• Working with:

g

• Working with:– Companies

• Alabama Laser• HighYAG

R h– Researchers• ARL Penn State• EWI

• Lincoln Technologies– Power Sources– Consumables– “The Process”

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Lincoln Electric’s Activities in Laser Processing

How Lasers “Fit” Lincoln Electric• New potential market(s) for Lincoln Products

C bl

Lincoln Electric s Activities in Laser Processing

– Consumables– Power supplies– Automation cells

CapabilitiesCapabilities• Automation Division

– Workcell• 10 kW IPG Photonics laser• HighYAG Hybrid welding head• Fanuc robot

Workcell at Lincoln Electric;Automation Division

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Hot Power Sources

• Hot Power Sources

Hot Power Sources

Hot Power Sources

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Hot Power SourcesHot Power Sources

Hot Wire Laser Processing-Historically

Technology has been around since– Technology has been around since the 1980’s

– Limited acceptance– Previous efforts were for filler– Previous efforts were for filler

addition for gap and for chemistry/metallurgical control

Two-1.5” Deep Hot Wire Laser Multi Pass Weld;

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Multi-Pass Weld;Westinghouse R&D 1987

Hot Power Sources

• “What Changed?”Ad d fib d li d

Then NowHot Power Sources

– Advanced fiber delivered, high powered lasers

– Digital power supplies• Old power supplies did• Old power supplies did

not monitor the process• New power supplies have

ability to monitor and t l Li lcontrol process; Lincoln

Waveform– Allows to maximize the

heat in the wire– Prevents arcing– Maximize wire feed

speed

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Hot Power Sources

• Digital Power Supplies

Hot Power Sources

Digital Power Supplies– Solid state control

• Ability to “change” the output as the process changes

WeldingPowerSupply

LaserPowerSupplyprocess changes

• Not only different modes (i.e. GTAW, GMAW, etc…) of welding but different

Supply

Welding PowerSupply Output Laser Output

“Condition”welding but different responses

– Feedback from process• Monitoring at 120 kHz• Algorithms

Welding Feedback

WeldingOutput/

Feedback

LaserOutput

Feedback

• Algorithms /”waveforms”

• Prevent arcing

Current, Voltage, Wire Feed Speed, etc.. Hot Wire Cladding Operation

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Hot Power Sources

• Digital Power SuppliesLaser Controls &Command Reference Laser Feedback & Status

Hot Power Sources

Digital Power Supplies– Solid state control

• Ability to “change” the output as the process changes

Interconnect/Interface

Command Reference Laser Feedback & Status

Laser Power Supply

Welding Power Supply

process changes• Not only different

modes (i.e. GTAW, GMAW, etc…) of welding but different

Welding Output

LaserWelding

Laser Output

welding but different responses

– Feedback from process• Monitoring at 120 kHz• Algorithms

Laser Output

WeldingOutput

Welding Feedback:Current, Voltage,Wire feed speed, etc

Laser Feedback:Power, temperature

• Algorithms /”waveforms”

• Prevent arcingLincoln Patent

Application #12254067 filed on 10/20/08

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Hot Power Sources

• Laser Beam Laser Beam

Hot Power Sources

– Low power density– Approximately equal to clad

Torch

Approximately equal to clad width

Travel Direction

• Wire– Heat by resistanceHeat by resistance

• “Electrons are cheaper than photons?”

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p

Hot Power Sources

• Experiments-

Hot Power Sources

1. Conventional TIG machine .vs. Hot Wire mode.2. Explore regulation modes3. Find Optimum Hot Wire Setting

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Hot Power Sources

• High Speed Camera

Hot Power Sources

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Hot Power Sources

• WeldDAQ

Hot Power Sources

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Hot Power Sources

• Experiment #1

Hot Power Sources

Conventional TIG machine .vs. Hot Wire mode.TIG = 200 amps Hot Wire = 2 KW

Process Parameters 045 Bl e Ma ™ 316LSi.045 Blue Max™ 316LSi

No gas shieldLaser power- 6 kWLaser optics- SameTravel speed- 55 ipmp p325 ipm wfs (9 lbs/hr)

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Hot Power Sources

Conventional TIG Output

Hot Power Sources

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Hot Power Sources

Conventional TIG Output

Hot Power Sources

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Hot Power Sources

Laser power source

Total Power = 7.6 KW

Hot Power Sources

Hot wire power source

6KW

Feeder

200a x 8v = 1.6KW

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Hot Power Sources

Laser power source

Total Power = 10.4 KW

Hot Power Sources

Hot wire power source

6KW

Feeder

200a x 22v = 4.4KW

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Hot Power Sources

Hot Wire Mode

Hot Power Sources

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Hot Power Sources

Hot Wire Mode

Hot Power Sources

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Hot Power Sources

Hot Wire Mode

Hot Power Sources

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Hot Power Sources

• Experiment #1

Hot Power Sources

– Use of GTAW Mode• Arcing causes runaway condition• Limits the use of “cheap” electronsp• Limits increase in deposit rates available.

– Laser Hot Wire Clad Mode• “Arcing Events” are controlled• Arcing Events are controlled• Use more “cheap” electrons and less “expensive” laser power• Extend the useable range of deposit rates

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Hot Power Sources

• Experiment #2

Hot Power Sources

Study various regulation modes.Current / Voltage / Power

Process Parameters VI Operation: 190a / 8.5v.045 Blue Max™ 316LSiNo gas shieldLaser power- 6 kWLaser optics- SameTravel speed- 55 ipm325 ipm wfs (9 lbs/hr)325 ipm wfs (9 lbs/hr)

Output: Std Dev Heating on Wire

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Hot Power Sources

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Regulation modes testedHot Power Sources

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30 CCPower

15

20

Volts

CV O ti S

5

10CV Operation Space

00 50 100 150 200 250 300 350 400

Current

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Hot Power Sources

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Regulation modes tested (CV w/ slope)Hot Power Sources

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30

15

20

Volts

O ti S

5

10Operation Space

00 50 100 150 200 250 300 350 400

Current

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Hot Power Sources

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Regulation modes tested (CC w/ slope)Hot Power Sources

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30

15

20

Volts

O ti S

5

10Operation Space

00 50 100 150 200 250 300 350 400

Current

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Hot Power Sources

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Regulation modes testedHot Power Sources

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30 CCPower

15

20

Volts

CV O ti S

5

10CV Operation Space

00 50 100 150 200 250 300 350 400

Current

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Hot Power SourcesResults

Run # SLOPE Regulation Input AMPS VOLTS STANDARD

Hot Power Sources

Run # SLOPE Regulation Type

Input AMPS VOLTS STANDARD POWER DEV

1 Power 1.7 204 8.17 0.04672 0 CV 8 5 165 8 4 0 07892 0 CV 8.5 165 8.4 0.07893 1 CV 10.4 170 8.6 0.0824 2 CV 12.3 207 8 0.0515 3.94 CV 16 199 8.04 0.04746 10 CV 27 5 183 7 78 0 0466 10 CV 27.5 183 7.78 0.0467 19.2 CV 45 194 7.6 0.0498 0 CC 200 201 7.53 0.0569 118 CC 300 205 7.87 0.25

10 235 CC 400 207 8.22 0.32811 470 CC 600 211 9.3 0.428

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Hot Power Sources

• Experiment #2

Hot Power Sources

– Tested Power / Voltage / Current regulation• Simplest to set: Power• Lowest Std Dev of Heating: Powerg• Most stable by observation: Power

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Hot Power Sources

• Experiment #3

Hot Power Sources

Hot Wire mode at Various Power Levels.Hot Wire = 1.5KW, 2 KW, 2.4 KW

Process Parameters .045 Blue Max™ 316LSiNo gas shieldLaser power- 6 kWLaser optics- SameTravel speed- 55 ipm325 ipm wfs (9 lbs/hr)325 ipm wfs (9 lbs/hr)

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Hot Power Sources

Hot Wire Mode 1.5 KW

Hot Power Sources

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Hot Power Sources

Hot Wire Mode 1.5 KW

Hot Power Sources

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Hot Power Sources

Hot Wire Mode 2 KW

Hot Power Sources

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Hot Power Sources

Hot Wire Mode 2 KW

Hot Power Sources

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Hot Power Sources

Hot Wire Mode 2.4 KW

Hot Power Sources

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Hot Power Sources

Hot Wire Mode 2.4 KW

Hot Power Sources

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Hot Power Sources

• Experiment #3

Hot Power Sources

– Maximize use of “Cheap Electrons”– Varied hot wire power level

• Too low: Push back• Optimum: Some “arcing events” but stable• Too high: Events cause puddle instability

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Hot Power Sources

• The “Take Aways”

Hot Power Sources

– Hot Wire Power Sources extend the useful range of “cheap electrons”. (More deposit rate)

– Power Regulation is more stable.– With Arc Suppression: Optimum power setting will contain

some “Arcing events” (<10 hz)

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Hot Wire Laser

• ApplicationsApplications

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Comparison Between TechnologiesComparison Between Technologies

• Major ProcessesS b A– Sub-Arc

– Strip Cladding– The Cladiator™– GMAW– Laser Powder– TIG– Laser w/ Powder– Plasma Spray– FCAW– Stick Electrode (SMAW)

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Comparison Between TechnologiesAdvantages: Hot Wire Laser• Laser results at GMAW deposit rates

Comparison Between Technologies

Laser results at GMAW deposit rates– Low heat input– Low distortion

Small / precise bead si e &

500

600

Fusion Line

– Small / precise bead size & placement

– Hard to weld applications

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200

300

400

VHN

HAZ Base Material

Clad Material

Layer 1Layer 2Layer 3

– Dissimilar metals– Zero spatter– Easy to feed filler

00 2000 4000 6000 8000 10000 12000 14000

Location in Clad (microns)– No overspray– Near 100% efficiency

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Hot Wire Laser

Applications

Hot Wire Laser

Applications• Mild Steel: Super Arc® L50, L56, LA100

– High quantity / high speed joining– Galvanized

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Hot Wire Laser

Applications:

Hot Wire Laser

Applications:• Blue Max® Stainless, Metrode® Duplex Stainless

– Corrosion Resistance• Cladding • Joining dissimilar metals

• Techalloy ® Nickel Based Alloys• Additive Mfg• Cladding• Cladding• Joining

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Hot Wire Laser

Applications

Hot Wire Laser

Applications• Wear Resistant Wires: Lincore®

– Abrasion– Metal to Metal– Impact

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Summary and ConclusionsSummary and Conclusions

1. Invite Paul Denney back next year!1. Invite Paul Denney back next year!2.Lasers are a growth opportunity.3 Hot Wire Power Source Developments3.Hot Wire Power Source Developments4.Hot Wire Applications

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