Surface structuring by remelting with laser radiation is a new approach to shape metallic surfaces ("WaveShape"). In this structuring process, surface material is reallocated in its molten state instead of being removed, because the process is based on the new active principle of remelting. The surface structure and the microroughness result from a laser-controlled melt pool due to surface tension. Basic research has been conducted with promising results, especially for the hot work steel 1.2343. Since remelting is a thermally driven process, significant differences between metallic materials were expected due to their thermophysical properties such as thermal conductivity, absorption coefficient, viscosity, heat capacity, etc. Therefore, the presented research soughed to expand the spectrum of processable materials. Within the framework of our investigation, we compared the achieved structure height as well as melt pool dimensions for six different materials. Furthermo re, we successfully tested new structuring strategies such as not linearly shaped scanning vectors to create innovative surface structures on all materials investigated. The biggest structures were achieved on the titanium alloy Ti6Al4V and the nickel based super alloy IN718. Finally, an approach of reverse structuring was investigated in order to erase existing structures and achieve a smoothed rewriteable metallic surface. The results show that surface structuring by laser remelting is well suited to process a wide range of different metals and to achieve a broad variety of different structures as well as to effectively erase existing surface structures such as milling marks
Laser material deposition (LMD) is a widely used coating process in industry. However, to increase its economic appeal, higher process speeds are required. The solution to this challenge is an innovative modification known as extreme high-speed laser material deposition (EHLA). EHLA allows for an impressive increase in process speed from 2 m/min for conventional LMD to 500 m/min. With the ability to adjust process parameters, EHLA can generate tailor-made surface properties, expanding its potential application beyond current industrial uses. In this novel study, we explore the effects of relative positioning between tools (laser beam and powder–gas jet) and substrate on the surface properties of EHLA coatings. By laterally and axially offsetting the tools, the proportional energy coupling of the laser radiation into the powder–gas jet and substrate can be modified. Altering the position of the powder–gas jet can also affect the weld pool flow or number of particle attachments, thereby affecting surface properties. This approach allows for the adjustment of surface roughness over a wide range—from smooth, quasi-laser-polished surfaces to rough surfaces covered with particle adhesions.
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