Laser cladding

ILT

Process and applications

Process Laser cladding is a deposition welding process in which a layer of powder is deposited on the substrate material, and the two materials are fused by metallurgical bonding through the action of a laser beam. The characteristic features of this process are: highly precise, automated deposition of a layer of material with a thickness varying between 0.1 millimeters and several centimeters metallurgical bonding of the cladding material with the base material absence of undercutting low heat input into the substrate a wide selection of homologous and non-homologous powder materials the ability to process virtually any type of metal alloy By varying the process parameters and selecting different powder materials, a components surface can be either alloyed or cladded with a carbide or similar coating. Typical deposition rates lie in the region of several cm2 per minute for layers with a thickness of around 1 mm.

Laser systems Laser cladding systems employ CO2, Nd:YAG or diode lasers with an output of between 100 watts and several kilowatts, operating in pulsed or continuous mode. Cartesian systems with 3-5 axes and robotic manipulators are employed as handling systems. NC programs are produced in several ways, either by direct input of the CAD data for the component, or by mapping the geometry of the components in an automated digital process, or by teaching of the NC paths. In a downstream step, CAM software specifically designed to accommodate the specific built-up strategies required for laser cladding generates the NC programs and post-processes the data for use in different manufacturing setups. Different powder feeding systems are used, depending on the complexity and the accessibility of the parts to be processed.

Applications The main fields of application are to be found in machine-tool and plant engineering, and engine manufacturing for the aircraft and automotive industries.
Above: Laser-clad mold insert. Middle: Laser-welded rough-processed substrate for brake-disk prototypes. Below: Repair of a separator drum.

Laser cladding can be used for a wide variety of purposes, including the application of wear-resistant or anticor rosion coatings, the repair of worn or poorly machined workpieces, deposition welding of shaped parts, and the complete manufacture of 3-D components.
Laser-clad high-pressure turbine blade (TIP repair).

Powder feed nozzles

In laser cladding by powder deposition, the way in which the powder is introduced into the melt pool is of great importance. This factor significantly affects the consumption of powder material, the extent to which oxidation occurs through reaction with the surrounding atmosphere, and the roughness of the cladded layer. Researchers at the Fraunhofer ILT and the Chair for Laser Technology LLT at RWTH Aachen University have developed a number of concepts for powder nozzles and implemented them in industrial-scale products. The nozzles are based on a modular structure that allows individual components to be replaced simply and quickly. The integrated watercooling system allows the nozzles to remain in continuous service for several hours.

Discrete coaxial nozzle In the discrete coaxial nozzle, a composite beam consisting of at least three side beams running coaxially to the laser beam is used to create a powder focus. Its most important features are: capacity for 3-D processing, in which the nozzle is slanted by up to 180 especially suited to the cladding of broad tracks (2 - 7 mm) integrated shielding gas control

Continuous-feed coaxial nozzle In continuous-feed powder injection, the powder is applied through a conical ring-shaped cavity that narrows as it approaches the tip of the nozzle. As a result, the powder is deposited in a donut-shaped cone around the laser beam. The continuous-feed nozzle enables the powder focus to be reduced to approx. 1 mm. Its most important features are: 3-D machining possible, with the nozzle slanted by up to 20. particularly well suited to the cladding of narrow tracks (< 1 mm). integrated shielding gas control.

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Off-axis powder nozzle In the off-axis powder nozzle, the powder is introduced laterally into the path of the laser beam. The nozzles main features are: Impingement angle variable between 50 and 80 Excellent accessibility to the component by small design of the nozzle (width 3 mm) Choice of modular nozzles with circular and rectangular injection openings
Optical system for processing internal contours.

Above: Off-axis powder nozzle with positioning unit. Middle: Discrete coaxial nozzle (three-way nozzle) with HighYAG optics for fiber-coupled diode laser. Below: Continuous-feed coaxial nozzle.

Special optics for processing internal contours A special optical system with its own powder feed unit has been developed for hardening and cladding applications. It is designed for use with a fibercoupled laser with an output of up to 3 kW. It is capable of processing components with an internal diameter of 50 mm or greater.
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Fraunhofer ILT your partner in laser technology

With 58 research institutes, 12.700 employees and over 1 billion euros research budget, the FraunhoferGesellschaft belongs to one of the leading organizations in Europe for contract research. Fraunhofers experts develop technical and organizational solutions to the problems set by industrial contractors up to the installation of complete systems. The Fraunhofer-Institut fr Lasertechnik ILT (Fraunhofer Institute for Laser Technology) develops methods and systems for laser material processing and laser measuring technology within the framework of R&D contracts. The know-how of 250 employees as well as state-ofthe-art technology are made available to the contractor.

Contact Dr. Konrad Wissenbach Phone: +49 (0)241/8906-147 konrad.wissenbach@ilt.fraunhofer.de Dipl.-Ing. Gerhard Backes Phone: +49 (0)241/8906-410 gerhard.backes@ilt.fraunhofer.de Dr. Andres Gasser Phone: +49 (0)241/8906-209 andres.gasser@ilt.fraunhofer.de Akad. Rat z. A. Dr. Ingomar Kelbassa Phone: +49 (0)241/8906-356 ingomar.kelbassa@ilt.fraunhofer.de Dr. Andreas Weisheit Phone: +49 (0)241/8906-403 andreas.weisheit@ilt.fraunhofer.de

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Fraunhofer-Institut fr Lasertechnik ILT Director Prof. Dr. rer. nat. Reinhart Poprawe M.A. Steinbachstrae 15 52074 Aachen Phone: +49 (0)241/8906-0 Fax: +49 (0)241/8906-121 info@ilt.fraunhofer.de www.ilt.fraunhofer.de Subject to alterations in specifications and other technical information. 06/2007.