Laser Metal Deposition (LMD) or laser cladding is a technology capable of coating, repairing and manufacturing components by injecting molten metal powder on a substrate. Some of the advantages of this technology are: wide range of materials available in powder, reduced thermal distortion, coatings and repaired parts of high quality. However, the biggest advantage can be its relative ease of implementation in a multiprocess machine tool and subsequent automatization.
The supply of hybrid machines in the world market that implements the LMD process is increasing (IBARMIA, DMG MORI, MAZAK, OKUMA, etc...), making the production more flexible in a single machine and introducing this process in more applications and industrial sectors.
However, hybridization also presents problems that are difficult to solve. Some of the most noteworthy are those associated with the use of powdered metallic material both from the point of view of the safety and hygiene of the operators and also of the waste management and integrity of the machine itself, being its most serious effects at lower efficiency of the process.
In this article, the study of the efficiency of different LMD nozzles is addressed for the coating of a hardened steel using for it the hybrid multiprocess machine IBARMIA ZVH45 /1600 Add + process, with the aim of finding the most efficient and, therefore (the one that generates less waste) and which, in turn, offers good productivity.
Keywords: Laser cladding, hybrid manufacturing, LMD, coatings, hardened steel, wear resistance, coaxial nozzle.
The consequences of gravity and the nozzle inclination angle in the powder-fed Directed Energy Deposition (DED) process were examined in this study. We also sought to define guidelines and manufacturing strategies, depending on the DED system configuration and the nozzle type. To do so, two nozzle types were used: a continuous coaxial nozzle with a slit of 0.5 mm and a four-stream discrete coaxial nozzle. Although the main effects of the configurations and the nozzles are well-known, their effects on the clad characteristics and the deposition strategy are as yet unclear. In this paper, measurements of a single clad and the effects of different deposition strategies on cladding applications and inclined walls are presented, and the consequences for manufacturing processes are discussed. Based on a complete study of a single clad, working vertically, five different tilted deposition strategies were applied: three to a single clad and two to an inclined wall. The results for both the single clad and the inclined wall reflect a pattern of changes to height, width, area, and efficiency, at both small and large nozzle angles and deposition strategies. The inclined wall presents a maximum horizontal displacement that can be reached per layer, without geometrical distortions. The amount of material per layer has to be adapted to this limitation.
Laser metal deposition (LMD) is an additive manufacturing process that allows the manufacturing of near-net-shape products. This could mean significant savings in terms of materials and costs in the manufacturing of high-performance components for the aeronautical industry. In this work, an analysis of how the LMD processing of alloy 718 affects the final machining has been carried out. For this purpose, a comparative study has been done by means of the monitoring of the end milling process of a part manufactured by LMD and a rough-milled part from forged material. Differences between process outputs such as chip morphology and cutting forces were studied. Material characteristics such as microstructure, hardness and mechanical properties were also analyzed.
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