In this paper, the results of experimental characterization of an optical system consisting of a chromatic confocal displacement sensor integrated with an optical laser head are presented. As a result of integration, the part of the optical path of the displacement sensor was combined with the optical path of the laser beam. Consequently, a working distance of 250 mm for the optical system was achieved. The main aim of the characterization was to determine the calibration curve, as well as the application parameters of the system. The methodology for spectral data processing with particular emphasis on the effectiveness of various extraction algorithms is presented. The Lorentzian fitting was considered as the optimal algorithm for the optical system. Consequently, a large measuring range of 10 mm was obtained with perfect linear tendency of the calibration curve. The optical system was characterized by high accuracy equal to ± 0.11 % of the measuring range, as well as 1 µm resolution. Moreover, the functionality of the system was verified on materials commonly used in laser processing and additive manufacturing. Finally, the system was validated through a comparative measurement with a laser profiler.
In this paper, the methodology for design of the system consisting of chromatic confocal displacement sensor integrated with an optical laser head was presented. Furthermore, the results of experimental characterization of optical components of the laser head were also included in the numerical analysis. The designed chromatic confocal displacement sensor was analyzed as an assembly of components widely available on the optical market. Nevertheless, the main goal of the numerical optimization was to determine the influence of individual components of the optical path of the system on its parameters, i.e., measuring range, FWHM of the characteristic spectral peak, and intensity that reaches the detector. The optimized solution was characterized in order to determine the calibration curve, as well as other important application parameters of the system. Moreover, taking into consideration the integration aspect the caustic of the laser beam shaped by the laser head was measured. Finally, the versatility of the system was presented and discussed.
Purpose The purpose of this paper is to propose cold spraying and laser cladding processes as alternatives to cadmium and chromium electroplating, respectively. There are many substances or chemicals within the coating technology that can be identified as substances of very high concern because of their carcinogenic or mutagenic nature. Cadmium and chromium undoubtedly belong to these items and are the basic constituents of electrolytic coating processes. Finding an alternative and adapting to the existing restrictions of the usage of such hazardous products stands for many to be or not to be in the market. Design/methodology/approach The research work was focused on down selecting the appropriate materials, producing the coating samples, testing their properties and optimizing process parameters by statistical method. On the one hand, the high-pressure cold spray system and spraying of the titanium coating on the landing gear component, and on the other hand, the high-energy laser cladding facility and the wear resistant cobalt-based coating deposited onto the shock absorber piston. Substrates of these two applications were made of the same material, 4330 – high-strength low-carbon steel. Findings Meeting the requirements of Registration, Evaluation, Authorization and Restriction of Chemicals implies undertaking research and implementation work to identify alternative processes. The work provides the technical characteristics of new coatings justifying application readiness of the researched processes. Originality/value Taguchi’s design of experiment method was combined with the measurements and analysis of specified coating properties for the optimization of the cold spray process parameters. There is also laser cladding process development presented as a fast rate technology generating coatings with the unique properties.
Part 4: Optimization, TuningInternational audienceOur aim is present the methodology of simulations for repetitive processes and tuning control systems for them in the presence of noise. This methodology is applied for tuning a laser power control system of the cladding process. Even the simplest model of this process is nonlinear, making analytical tuning rather difficult. The proposed approach allows us to select quickly the structure of the control system and to optimize its parameters. Preliminary comparisons with experimental results on a robot-based laser cladding systems are also reported. These comparisons are based on the temperature measurements, observations by a camera and IR camera
Technologia napawania laserowego polega na wykorzystaniu wiązki laserowej celem precyzyjnego nałożenia warstwy materiału o podwyższonych właściwościach na podłoże. Szczególne zainteresowanie budzi ona w branży lotniczej. Odpowiednie przygotowanie procesu wiąże się z wykonaniem testów symulacyjnych z wykorzystaniem modeli przepływu dwufazowego oraz interakcji wiązki laserowej z materiałem. Następnie zostają wyznaczone ścieżki ruchu głowicy przy użyciu dedykowanych narzędzi CAD/CAM. W ramach analizy technologii napawania laserowego dla zastosowań branży lotniczej przedstawiono nakładanie powłok funkcjonalnych, będących alternatywą dla chromu elektrolitycznego. Przeanalizowano również metodę regeneracji wierzchołka łopatki turbiny silnika odrzutowego. Zaprezentowano też możliwości obróbki hybrydowej w wytwarzaniu przyrostowym tytanowych komponentów lotniczych oraz metodę monitorowania temperatury celem jakościowej kontroli procesu.
StreszczenieTechnologia ultraszybkiego napawania laserowego stanowi rozwinięcie metod deponowania powłok funkcjonalnych przy użyciu wiązki lasera. Charakteryzuje się ona wysokimi prędkościami procesu, pozwalając uzyskiwać znaczne szybkości chłodzenia oraz niewielkie wymieszanie z podłożem, co prowadzi do dużej czystości materiału powłoki i lepszych własności nałożonej warstwy w porównaniu z konwencjonalnym napawaniem laserowym. W niniejszym artykule przedstawiono technologię ultraszybkiego napawania laserowego w aplikacji dla przemysłu lotniczego. Zaprezentowano opracowane stanowisko do realizacji procesu oraz weryfikację technologii na komponencie podwozia samolotu, modyfikowanym w ramach projektu AMpHOra. Uzyskane rezultaty wskazują, że otrzymane tą technologią powłoki mogą stanowić alternatywę względem powłok elektrolitycznych z twardego chromu. Słowa kluczowe: napawanie laserowe; powłoki funkcjonalne; lotnictwo AbstractUltra-High-Speed Laser Cladding technology is one of the developments of functional coating deposition methods with usage of laser beam. It is characterized by high cladding velocities, allowing to obtain a significant cooling rates and low dilution, which leads to high purity of the clad and thus increase of properties of the deposited coating in comparison with the conventional laser cladding. In this paper a technology of Ultra-High-Speed Laser Cladding has been shown in case of applications for the aviation industry. The developed setup for the process has been presented and verification of the technology on the airplane chassis component for AMpHOra project has been discussed. The obtained results shown indicate that the coating received via this technology may compete with hard chrome plating.
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