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