laser additive manufacturing for remanufacturing of critical …€¦ · additive manufacturing...
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Laser Additive Manufacturing for Remanufacturing of Critical ComponentsBingbing Li, Assistant ProfessorCalifornia State University Northridge
Research Highlights
Sustainable design and manufacturing, sustainability analysis of nanotechnologies, life cycle assessment, and manufacturing energy efficiency
Additive manufacturing (Laser cladding for remanufacturing, selective laser sintering/melting, fused deposition modeling, inkjet bioprinting)
Advanced manufacturing process, CAD/CAM, CNC. Nanomaterials/structure for energy conversion and storage
(lithium ion battery)
National Basic Research Program (973 Program)“Fundamental Scientific Research on Remanufacturing of Mechanical Equipment”, Ministry of Science and Technology of China, ¥38.0 million ($6.3 million), 2012-2016.
Laser additive manufacturing for remanufacturing of critical components
•Additive•Subtractive•Deformation
How can we make physical form?
National Additive Manufacturing Innovation Institute (NAMII)
The official announcement of the award came on August 16, 2012 at NCDMM’s Youngstown, Ohio facility and the headquarters of NAMII.
ASTM International Committee F42 on Additive Manufacturing Technologies defines additive manufacturing as the process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.
Desired Shape
Actual Shape from AM
Definition of Additive Manufacturing
Industries using RP
Additive Manufacturing Processes
1D scanning 1D Parallel 2D Area-Filling
Pattern Energy Vat PhotopolymPowder Bed FusionElectrochemicalDeposition
Mask-Projection VPSheet Lamination
Pattern Material Material Extrusion Material JettingBinder Jetting
Thermal Spray
Pattern both Material & Energy
Directed Energy Deposition
AM Process TypesASTM Standard Industry Names Vendors
Vat Photopolymerization Stereolithography 3D Systems, Envision TEC, FormLabs
Powder Bed Fusion Selective Laser SinteringLaser MeltingElectron Beam Melting
3D Systems, EOS, ARCAM, Renishaw
Material Extrusion Fused Deposition Modeling Stratasys, 3D Systems, Printrbot
Material Jetting MultiJet ModelingPolyJet
Stratasys, 3D Systems, Sanders
Binder Jetting 3D Printing 3D Systems, EX One, VoxelJet
Directed Energy Deposition Laser Engineered Net ShapingDirect Metal Deposition
Optomec, DM3D, Sciaky, Insstek
Sheet Lamination Laminated Object ManufacturingUltrasonic Consolidation
Mcor Technologies, CAM-LEM, Fabrisonic, Solido
Fundamental of Laser Cladding
Typical single layer thickness: 0.2-2.0 mm
Heat input in part: low-moderate
Dilution with substrate material: less than 5%
Adhesion: metallurgical boning Structure: completely dense Base materials: carbon steel,
alloyed steel, stainless, cast iron, nickel, alloys
Coating materials: Fe-, Co-, Ni-alloys, metal
Turnkey system of laser cladding equipment
Cladding System Components• Power source (Laser)• Power delivery (Optical
fiber)• Optics• Motion system• Powder feeder• Powder delivery nozzle
Laser
Optics
Nozzle
Motion system
Laser Model: YLS-2000 Laser type: optical fiberMaximum Power: 2000WWidth: 3nmNozzle: YC52
Remanufacturing is the process of disassembly and recovery at the module level and, eventually, at the component level. It requires the repair or replacement of worn out or obsolete components and modules.
A rough case analysis of a heavy duty diesel engine.
N e w R e m a n u f a c t u r e
C o s t R e d u c t i o n
E n e r g y S a v i n g
M a t e r i a l S a v i n g
E n v i r o n m e n t a l I m p a c t
ReduceSignificantly
Application: Remanufacturing
Rotor: 6.4 meter long, weighed 7 ton, value ¥120 million
Core Component of Typical High Value-added Mechanical Equipment
Cleaning
Abrading
Laser repair
Complete appliance
Denaturation
Fatigue
Surface interface
Cone Joint
BaringShaft Diameter Axis
BalancingDrum
ImpellerSeal
SealSleeve Locking
NutIm
pelle
r
Spa
cing
Pie
ce
Technical Challenge
Application: die cutter and blade in the rotary cutting die equipment
•PNV Machinery Co
Remanufacturing Process by Laser Cladding
Materials
Sample Powder Particle size (mesh) Density (g/cm3) Mobility (s/50g)1 Nickel base alloy #1 115 700 4.89 132 Iron base alloy #1 65-325 3.44 24.63 Iron base alloy #2 27-80 7.8 14
Table Properties of cladding powder
Sample Powder C B Cr Si Ni Mn Mo P O S Fe Cu1 Nickel base alloy #1 0.02 1 2 base 0.052 0.7 19.382 Iron base alloy #1 0.13 1.17 15.45 1.08 1.45 1.05 base3 Iron base alloy #2 0.2 1.2 15 1.05 2.0 0.75 1.3 base
Table Chemical composition of cladding powder
Substrate is steel C45, and cladding materials are Ni-base and Fe-base alloys
Experiment Process•To minimize the number of experiments and prevent high cost of experiments, it is designed against a three level Taguchi’s Orthogonal Array that required 9 specimens in total to be carried out.• Step 1: Adjust the laser to ensure it operate normally and keep the focal length of 300mm.• Step 2: Remove the rust and oxide layer on the surface with abrasive paper to achieve a
certain roughness, and clean the oil contamination with acetone.• Step 3: The types of powder, laser power (3, 4, 5 kW), rotate speeds (6.3, 7.9, 9.5 r/min,
corresponding to the scanning speed 400, 500, 600mm/min) are selected for experiments, as shown in Table 3 L9 (33) Taguchi orthogonal array. The substrate C45 with length 100mm and diameter 20mm was clamped on the workstation. Experiment is implemented by a CO2 laser (model Han’s Laser 6000) with spot size of 3mm and automatic feeding. The layer is fused by laser cladding nozzle as a multiple-layer coatings with thickness rang of 2.5-3.2mm.
# Sample Laser power (kW) Speed (rpm)1 1 3 6.32 1 4 7.93 1 5 9.54 2 3 7.95 2 4 9.56 2 5 6.37 3 3 9.58 3 4 6.39 3 5 7.9
Experiment Process
• Step 4: After laser cladding, both lateral surfaces of the clad layer of each substrate are cross sectioned to height 2mm for metallographic analyses. Then the round bar is cut into small pieces with total length 20mm by wire electrical discharging machine.
Schematic illustration of Experiment (h=2mm, ∅=20mm, clad layerthickness=2mm) The Actual Shearing Experiment
Experiment Process
Fracture behavior of the 9 specimens after shear strength test. Distribution points of hardness test
Experiment
# Sample Laser power (kW) Speed (rpm) Shear stress (MPa)1 1 3 6.3 423.62 1 4 7.9 468.43 1 5 9.5 592.54 2 3 7.9 964.25 2 4 9.5 1161.26 2 5 6.3 1203.27 3 3 9.5 1112.88 3 4 6.3 1081.89 3 5 7.9 946.4
Table Strength of orthogonal experimental design
Powder Laser power Scan rate
Strength
K1 1484.5 2500.6 2708.6K2 3328.6 2711.4 2379K3 3141 2742.1 2866.5R 614.7 80.5 162.5
Table Shear Strength
Results
(a) whole image (b) bond part of cladding layer and substrate c) cladding layerSEM of cladding layer of sample #4
-6 -5 -4 -3 -2 -1 0 1
100
200
300
400
500
600
700
Micr
o-ha
rdne
ss/H
V
Distance to surface/mm
1#6#
0 1 2 3 4 5 60
100
200
300
400
500
600
700
Micr
o-ha
rdne
ss /H
V
Distance of laser spot center/mm
1# 6#
Conclusion
The powder type has the largest dependency, followed by scanning speed. The laser output power has minimal impact.
The bonding strength with iron-based powder is much higher than that with the nickel-based powder. The bond strength increases as the laser power increases.
No obvious dependence of bonding strength on scanning speed has been found.
The micro hardness of both clad layer and bonding surface is higher than that of the substrate. Side effected zone is small in this research.