Advances in the understanding of the annular laser beam wire cladding process

Kotar, Matjaž; Fujishima, Makoto; Levy, Gideon; Govekar, Edvard

doi:10.1016/j.jmatprotec.2021.117105

Cited by 12 publications

(7 citation statements)

References 20 publications

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“…Applying a large focal spot area contributes to achieving a uniform temperature distribution with minimal gradients, influencing surface tension and viscosity, as noted by Goffin et al [86,87], who observed more effective substrate heating when using a larger Gaussian beam compared to a smaller one [83,92,93]. Kotar et al's experiment utilizing a continuous fiber laser further supports these findings, indicating that the smallest focal spot area results in a Gaussian distribution with the highest intensity at the wire axis, while increasing the focal spot area transforms the profile to a ring-type distribution with lower energy intensity at the center [85,94].…”

Section: Beam Irradiance and Focal Spot Sizementioning

confidence: 64%

“…The correlation between the dilution and power was supported by Ji et al, where an increase in the focal distance decreased the dilution [100], and by Demir et al, where an increase in pulse duration resulted in higher dilution [66]. Kotar et al observed that constant energy input during the process leads to heat accumulation and a gradual increase in dilution [85].…”

Section: Dilutionmentioning

confidence: 89%

“…Chen et al's investigation reveals that annular beams require less laser power to melt the same amount of fed wire compared to the Gaussian distribution. This is particularly beneficial due to their lower peak energy density and more uniform energy distribution, providing a lower thermal gradient in the molt pool [84,85]. Goffin et al compared a pedestal beam with a Gaussian beam to investigate the effect each has on melt pool formation and found that a pedestal beam heats the substrate more efficiently compared to a Gaussian beam with the same width.…”

Section: Laser Beam Profilementioning

confidence: 99%

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A Review on Wire-Laser Directed Energy Deposition: Parameter Control, Process Stability, and Future Research Paths

Ghanadi,

Pasebani

2024

JMMP

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Wire-laser directed energy deposition has emerged as a transformative technology in metal additive manufacturing, offering high material deposition efficiency and promoting a cleaner process environment compared to powder processes. This technique has gained attention across diverse industries due to its ability to expedite production and facilitate the repair or replication of valuable components. This work reviews the state-of-the-art in wire-laser directed energy deposition to gain a clear understanding of key process variables and identify challenges affecting process stability. Furthermore, this paper explores modeling and monitoring methods utilized in the literature to enhance the final quality of fabricated parts, thereby minimizing the need for repeated experiments, and reducing material waste. By reviewing existing literature, this paper contributes to advancing the current understanding of wire-laser directed energy deposition technology. It highlights the gaps in the literature while underscoring research needs in wire-laser directed energy deposition.

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Section: Beam Irradiance and Focal Spot Sizementioning

confidence: 64%

Section: Dilutionmentioning

confidence: 89%

Section: Laser Beam Profilementioning

confidence: 99%

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A Review on Wire-Laser Directed Energy Deposition: Parameter Control, Process Stability, and Future Research Paths

Ghanadi,

Pasebani

2024

JMMP

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“…The powder feeding, laser cladding laser energy absorption rate is high, easy for automating the control, but the powder utilization rate is not high, and the quality of the powder requirements are high. Laser wire melting [ 19 ] uses metal wire as the material, and compared with powder as raw material, it has the advantages of high processing efficiency, high material utilization, a large degree of freedom in production, good surface-forming quality, high production efficiency, no powder pollution, and so on, and it has been widely studied [ 20 , 21 , 22 , 23 ]. In addition to the laser melting of pure metal wires, some researchers have also carried out laser melting studies on core-spun wires [ 24 ].…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Wear Resistance of Si-TC4 Composite Coatings by High-Speed Wire-Powder Laser Cladding

Men,

Sun,

et al. 2024

Materials

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The hardness and wear resistance of the surface of TC4 titanium alloy, which is widely used in aerospace and other fields, need to be improved urgently. Considering the economy, environmental friendliness, and high efficiency, Si-reinforced Ti-based composite coatings were deposited on the TC4 surface by the high-speed wire-powder laser cladding method, which combines the paraxial feeding of TC4 wires with the coaxial feeding of Si powders. The microstructures and wear resistance of the coatings were analyzed using X-ray diffraction (XRD), scanning electron microscopy (SEM), Vickers hardness tester, and friction and wear tester. The results indicate that the primary composition of the coating consisted of α-Ti and Ti5Si3. The microstructure of the coating underwent a notable transformation process from dendritic to petal, bar, and block shapes as the powder feeding speed increased. The hardness of the composite coatings increased with the increasing Si powder feeding rate, and the average hardness of the composite coating was 909HV0.2 when the feeding rate reached 13.53 g/min. The enhancement of the microhardness of the coatings can be attributed primarily to the reinforcing effect of the second phase generated by Ti5Si3 in various forms within the coatings. As the powder feeding speed increased, the wear resistance initially improved before deteriorating. The optimal wear resistance of the coating was achieved at a powder feeding rate of 6.88 g/min (wear loss of 2.55 mg and friction coefficient of 0.12). The main wear mechanism for coatings was abrasive wear.

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“…The study of the effects of defocusing and WIP in coaxial deposition has been generally concentrated on the study of process stability [9][10][11][12][13][14], bead geometry and substrate dilution [12,14], and mechanical properties [14]. Kotar et al found that, with increasing WIP, the stability process window becomes larger, as indicated by the increase in the range of minimum to maximum allowed laser power for a fixed wire feed rate and traverse feed rate [12]. This work also found that, with all other variables held constant, WIP did not have an impact on bead width and height over the tested ranges but rather only had an impact on the substrate dilution.…”

Section: Introductionmentioning

confidence: 99%

Effects of Laser Defocusing on Bead Geometry in Coaxial Titanium Wire-Based Laser Metal Deposition

Mathenia,

Flood,

McLain

et al. 2024

Materials

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Coaxial wire-based laser metal deposition is a versatile and efficient additive process that can achieve a high deposition rate in the manufacturing of complex structures. In this paper, a three-beam coaxial wire system is studied, with particular attention to the effects of deposition height and laser defocusing on the resulting bead geometry. As the deposition standoff distance changes, so does the workpiece illumination proportion, which describes the ratio of energy going directly into the feedstock wire and into the substrate. Single titanium beads are deposited at varying defocus levels and deposition rates and the bead aspect ratio is measured and analyzed. Over the experimental settings, the defocusing level and deposition rate were found to have a significant effect on the resulting bead aspect ratio. As the defocusing level is increased away from the beam convergence plane, the spot size increases and the deposited track is wider and flatter. Process parameters can be used to tune the deposited material to a desired aspect ratio. In coaxial wire deposition, defocusing provides an adjustment mechanism to the distribution of heat between the wire and substrate and has an important impact on the resulting deposit.

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Advances in the understanding of the annular laser beam wire cladding process

Cited by 12 publications

References 20 publications

A Review on Wire-Laser Directed Energy Deposition: Parameter Control, Process Stability, and Future Research Paths

A Review on Wire-Laser Directed Energy Deposition: Parameter Control, Process Stability, and Future Research Paths

Microstructure and Wear Resistance of Si-TC4 Composite Coatings by High-Speed Wire-Powder Laser Cladding

Effects of Laser Defocusing on Bead Geometry in Coaxial Titanium Wire-Based Laser Metal Deposition

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