wire vs. powder in lmd...powder lmd process principle process characteristics typical process high...
TRANSCRIPT
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WIRE VS. POWDER IN LMD
LAM 2018, 29. March 2018, Schaumburg
M. Sc. Jana Kelbassa, Dr. Andres Gasser, Dr. Norbert Pirch
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Fields of Application Laser Metal Deposition
INTRODUCTION AND STATE OF THE ART
RepairCoating AM
Surface coating & protection
Oil and gas
Chemical industry
…
Repair
Aerospace
Power generation
Tools & molds
…
Development of LMD processes
Tools & molds
Power generation
Aerospace
…
Current focus of work Development
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Technology description
Powder LMD
Process principle Typical processProcess characteristics
High diversity of additive materials
Applicable on sensitive surfaces
No undercut
Layers of 0,05 mm thickness up to several cm (multilayer)
Local application with low heat input and low modified base material properties
Automatable
Welding in constricted conditions
Layer based additive manufacturing also on 3D-surfaces
Coaxial powder feeding LMD
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Technology description
Wire LMD
Process principle Typical processProcess characteristics
Nearly 100 % material efficiency
No contamination of machine
Low costs for additive material
Good homogeneity of the material
Low safety and health issues
Local application with low heat input and low modified base material properties
Automatable
Layer based additive manufacturing also on 3D-surfaces
Easy combination with milling machine into hybrid machine
Coaxial wire feeding LMD
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MAIN TOPICS IN WIRE VS. POWDER IN LMD
Additve Material properties
− Powder
− Wire
System technology
− Powder feeding
− Wire feeding
Simulation
− Powder LMD process
− Wire LMD process
Results
Source: Fraunhofer IPT
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MATERIALS FOR POWDER LMD
Nickel base alloys− IN625, IN718, IN738, Hastelloy X, Waspaloy, Inconel
713, CM-247LC, Nimonic 263, Hastelloy C-276, Inconel 939, Haynes 230, MarM247
Titanium alloys− Ti-6-2-4-2, Ti-6-2-4-6, Ti-6-4, CP Ti
Aluminum base alloys− 4047, 6061, 7050, 7075, AlSi7Mg, AlSi10Mg, AlSi12,
Iron base alloys− 17-4PH, H13, 304L, 316L, 420SS, PH 138 Mo, 15-
5PH, AISI 4140 Cobalt-based:
− Stellite21, CM-64, Co6, CoCr Other-based:
− Cu-Ni (copper-based), A286 (iron-nickel-chromium alloy)
Powder materials (exemplary)
Atomization of nearly every metallic material is possible
Possibilities of material combinations
Source: LAM2012 Presentation 15
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INFLUENCE OF POWDER QUALITY ON LMD PROCESS RESULTS
2000 µm25X
25X
Supplier A
Supplier B
LMD carried out with– Identical process parameters– Identical process setup
Powder was obtained from two suppliers and specified with respect to:– Atomization technique (thermal inert-gas
atomization)– Chemical composition and residual
atmosphere– Nominal grainsize and morphology
LMD process with 13%Cr-Steel Powder
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MATERIALS FOR WIRE LMD
Alloy mixing in welding process
Wire stiffness high Reliable wire feeding Limited welding surface
quality (matt, oxidized, fine layer of particles)
Alloy present Wire stiffness low Challenging wire feeding Good welding surface quality
(glossy, no oxidation) High cost compared to filler
wire
Work hardened Manganese Alloys− T Fe10*, T Fe9*, etc.
Heat-treatable Tool steels− 1.2343, T Fe3*, T ZFe8*, etc.
Stainless ferritic und martensitic steels− 1.4820, T Fe7*, T Fe12*, etc.
Nickel base alloys− Inconel 718, T Ni2*, etc.
Abrasion-resistant steels− T Fe16*, T Fe20*, etc.
Copper Aluminum Alloys− T Cu1*, etc.
Cobalt base alloys− Stelloys, T Co1*, T Co2*, etc.
Titanium alloys− Ti6Al4V, etc.
Source: Fraunhofer IPT * Material designation Welding Alloy Group DIN EN 14700, T=filler wire, S=solid wire, WA=Welding Alloys
Wire materials (exemplary)
Generally there is a welding material for each material class.Unfortunately manufacturer specific configurations and names are common.
Comparison of solid wire and filler wire
Solid wireQuada QuInc 718
(Ø 1,2 mm)
Filler wireWA Stelloy 718-G
(Ø 1,2 mm)
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POWDER FEEDING SYSTEMS
Source: GTV Verschleißschutz GmbH
Disk powder feeder
powder feeding rate from0.5 to 300 g / min
Source: Medicoat AG
Powder feeder with oscillating conveyor
powder feeding rates from0.1 g/min to approx. 300 g/min
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POWDER FEEDING NOZZLES
5 mm 5 mm
off-axis coaxial-continuous coaxial-discrete
good accessibilitydirection dependent
small powder focus (less than 100 mm possible)
robust and suited for 3D-cladding
5 mm 5 mm 5 mm
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Characterizing the powder gas jet – setup
POWDER NOZZLE QUALIFICATION BY POWDER JET MEASUREMENT
Sensor module
Control module
PLCexhaustion
cameraoptics
axis
• PC
• Control
• Power supply
• safety
• …Illumination-laser
Illumination module
illumination
level 0
level 1
level 2
level 3
level 4
level 5
level 6
level 7
Laser line moved to each measurment level
level 8 …
Nozzle Tip
Laser Line enlightens a 200µm slice of the powder jet captured by a Camera
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Basic design variants for wire-based LMD
Feed direction
Wire feeding
Focusing optic
Laser beam
Inert gas
substrate
αD
x
yz
Feed direction
Wire feeding
Coaxial head
Laser beam
Inert gas
substrate
αL
αSG
x
yz
W-LMD with lateral wire feeding W-LMD with coaxial wire feeding
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PROCESSING HEADS FOR COAXIAL WIRE LMD
ring-shapedintensity
generation
focus
wire feed 1
3
4
5
2
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POWDER LMD MODELLING PHYSICAL PROCESSES
1) Beam propagation: I=I(x, y, z) 2) Particle density: n=n(x, y, z) 3) Interaction of laser beam with powder particles
Transmitted Intensity Itrans (x, y, z)
Temperature of particles
4) Equations: Transient heat flow Pressure balance Mass balance
5) Results Track geometry Temperature distribution Local solidification conditions Powder efficiency
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Tactile 3D-measurement
Measurement ofrectangularity, flatness
Referring to DIN EN ISO 1101
Form tolerances
Specimens built up in lying position
HT: referring to AMS 5662
Static load tests refering toDIN 50125
Mechanical propertiesSurface properites
Optical 3D-measurement
Measurement of surface rougness
Referring to DIN EN 4287,DIN EN 11562
5 mm20 mm 5 mm
PROCESS COMPARISONDirect comparison of LMD and SLM concerning following aspects:
ICTM AachenInternational Center forTurbomachinery Manufacturing
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COMPARISON OF POWDER AND WIRE LMD
Laser cladding processes
Metal deposition on 3D surface (layer-by-layer) Deposition on free-form parts Local application with correlating local heat input
and material property modification Potential for functional integration:
Light weight construction, heat- and mass transfer, subsequent individualization, sensor integration, etc.
Overhang and undercuts are possible but limited Support structures not necessary Direction independent material feed possible Theoretically unlimited building space with robotic
aided systems Combination with milling machines to hybrid
machines
Powder LMD
Material gradients possible Powder handling required
(contamination, respirable) No risk of collision powder
materials Limited material efficiency
Wire LMD
Material loss and contamination of the machine are low
Feedstock is free of defects Material efficiency 100 % Lower material costs Wire feeder prone to errors
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PROCESS OVERVIEW ULTRA-HIGH-SPEED LASER MATERIAL DEPOSITION
State of the art: EHLA for rotationally symmetric components (lathe functionality)
Coating to improve wear and corrosion resistance of e.g. shafts, disks, cylinders
Layer thickness 25 ... 500 µm
Small heat-affected zone, various material combinations possible
Conventional LMD EHLA
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Topics
Save the Date Speakers at Conference 2017
Industrie 4.0 with Regard to Manufacturing Turbomachinery Parts
Innovative Process Monitoring Systems
Advanced Machining
Innovative and Newly Developed Materials
Additive Manufacturing
Laser Based Repairs
Live Presentations
Outlook
ICTM ConferenceFebruary 6th-7th, 2019
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Thank you very muchfor your attention!
ICTM AachenInternational Center forTurbomachinery Manufacturing
Contact:
M. Sc. Jana KelbassaTel: +49 241 8906-8331Fax: +49 241 [email protected]