Comparison of laser cladding with powder and hot and cold wire techniques

Nurminen, Janne; Riihimäki, Jouko; Näkki, Jonne; Vuoristo, Petri

doi:10.2351/1.5060747

Cited by 17 publications

(10 citation statements)

References 4 publications

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“…Because the contact resistance between the wire and the baseplate is large and the current is constant, the largest amount of heat is generated in the contact area and the wire tip is melted first and fed into the molten pool which is generated by the laser heating. Moreover, the extremely hot metal wire increases the rate at which the metal absorbs the laser energy [ 40 , 41 ] and more energy can be put into the pool, thereby enhancing the energy utilization as a whole. As the hardness of the hot wire reduces and the bridging improves, the process of deposition becomes stable and smooth [ 42 , 43 ], thus achieving higher surface quality.…”

Section: Discussionmentioning

confidence: 99%

Low-Roughness-Surface Additive Manufacturing of Metal-Wire Feeding with Small Power

Wang

Zhu³

et al. 2021

Materials

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Aiming at handling the contradiction between power constraint of on-orbit manufacturing and the high energy input requirement of metal additive manufacturing (AM), this paper presents an AM process based on small-power metal fine wire feed, which produces thin-wall structures of height-to-width ratio up to 40 with core-forming power only about 50 W. In this process, thermal resistance was introduced to optimize the gradient parameters which greatly reduces the step effect of the typical AM process, succeeded in the surface roughness (Ra) less than 5 μm, comparable with that obtained by selective laser melting (SLM). After a 10 min electrolyte-plasma process, the roughness of the fabricated specimen was further reduced to 0.4 μm, without defects such as pores and cracks observed. The ultimate tensile strength of the specimens measured about 500 MPa, the relative density was 99.37, and the Vickers hardness was homogeneous. The results show that the proposed laser-Joule wire feed-direct metal deposition process (LJWF-DMD) is a very attractive solution for metal AM of high surface quality parts, particularly suitable for rapid prototyping for on-orbit AM in space.

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Section: Discussionmentioning

confidence: 99%

Low-Roughness-Surface Additive Manufacturing of Metal-Wire Feeding with Small Power

Wang

Zhu³

et al. 2021

Materials

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“…The advantages of the pulsed process and the temperature-time-regime are maintained. An approach to decouple heat sources is, for example, in the filler material by the hot-wire technology [11,12]. The hot-wire temperature should not exceed the softening or plasticizing temperature of the filler material, i.e., larger than 900 • C in case of HS 282, to guarantee a stable wire-feed.…”

Section: Introductionmentioning

confidence: 99%

“…Figure11. Dilution as function of pulse energy and hot-wire power for pulse shape 1 and wire-feeding rates of 4, 8 and 12 mm/s.…”

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confidence: 99%

Strategies for Increasing the Productivity of Pulsed Laser Cladding of Hot-Crack Susceptible Nickel-Base Superalloy Inconel 738 LC

Kästner

Neugebauer

Schricker

et al. 2020

JMMP

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A novel repair strategy based on decoupled heat source for increasing the productivity of wire-assisted pulsed laser cladding of the γ’-precipitation strengthening nickel-base superalloys Inconel 738 low carbon (IN 738 LC, base material) and Haynes 282 (HS 282, filler material) is presented. The laser beam welding process is supported by the hot-wire technology. The additional energy is utilized to increase the deposition rate of the filler material by increasing feeding rates and well-defining the thermal management in the welding zone. The simultaneous application of laser pulse modulation allows the precise control of the temperature gradients to minimize the hot-crack formation. Accompanying investigations such as high-speed recordings and numerical simulations allow a generalized statement on the influence of the adapted heat management on the resulting weld seam geometry (dilution, aspect ratio and wetting angle) as well as the formation of hot-cracks and lack of fusion between base and filler material. Statistical analysis of the data—the input parameters like laser pulse energy, pulse shape, hot-wire power and wire-feeding rate in conjunction with the objectives like dilution, aspect ratio, wetting angle and hot-cracking behavior—revealed regression functions to predict certain weld seam properties and hence the required input parameters.

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“…Laser hot-wire cladding (LHWC) as an alternative to LCWC can effectively increase the productivity and improve the stability of the deposition process. 15 In LHWC, the current flows from the torch through the wire which is heated up to near melting temperature by resistance between the conductive torch and the “grounded” substrate. 16 “Arcing events” caused by the over applied voltage should be eliminated.…”

Section: Introductionmentioning

confidence: 99%

“…Especially due to the increased interest in depositing large structures, this technique has been attracting more attention. Nurminen et al 15 compared three laser cladding methods with powder, cold wire, and hot wire and found that LHWC had the highest deposition rate. Nurminen et al 8 also studied the effects of material properties and electrical parameters on the preheating power.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation of laser hot-wire cladding

Liu

Kovacevic

2015

Proceedings of the Institution of Mechanical Engineers, Part B:

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Laser cladding by cold-wire feeding is known as an efficient cladding method due to its advantages, such as near 100% material utilization, high deposition rate, and flexible adaptation to the cladding position. However, it has very stringent requirements on the operative conditions, such as a small range of wire feeding rate and precise wire feeding position. The aim of this work was to investigate the laser hot-wire cladding technique, which improved the productivity and stability of the process significantly with respect to laser cold-wire cladding. The external preheating of the filler wire resulted in reduction in required laser power, a low dilution, and a higher deposition rate. A comparison was made between laser cold-wire cladding and laser hot-wire cladding of Inconel 625 on mild steel, with respect to the clad characteristics, microstructure, and hardness. An optimization of the main processing parameters in laser hot-wire cladding, such as the laser power, laser spot size, laser scanning speed, wire feeding orientation and position, wire preheating voltage, and wire feeding rate, was performed. The optimal parameters were used to create a multi-track deposit.

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Comparison of laser cladding with powder and hot and cold wire techniques

Cited by 17 publications

References 4 publications

Low-Roughness-Surface Additive Manufacturing of Metal-Wire Feeding with Small Power

Low-Roughness-Surface Additive Manufacturing of Metal-Wire Feeding with Small Power

Strategies for Increasing the Productivity of Pulsed Laser Cladding of Hot-Crack Susceptible Nickel-Base Superalloy Inconel 738 LC

Experimental investigation of laser hot-wire cladding

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