Improvement of strategies and parameters for multi-axis laser cladding operations

Calleja, A.; Tabernero, I.; Fernández, Ángel G.; Celaya, A.; Lamíkiz, Aitzol; Lacalle, Luís Norberto López de

doi:10.1016/j.optlaseng.2013.12.017

Cited by 83 publications

(45 citation statements)

References 14 publications

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“…For its development, research nowadays involves all kinds of areas, such as process optimization [5][6][7][8][9], modelling/simulation [10][11][12][13][14], and material microstructure and mechanical properties [15][16][17][18][19].…”

Section: Introductionmentioning

confidence: 99%

The Influence of the Powder Stream on High-Deposition-Rate Laser Metal Deposition with Inconel 718

Chen

Pirch

Gasser

et al. 2017

Metals

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Abstract:For the purpose of improving the productivity of laser metal deposition (LMD), the focus of current research is set on increasing the deposition rate, in order to develop high-deposition-rate LMD (HDR-LMD). The presented work studies the effects of the powder stream on HDR-LMD with Inconel 718. Experiments have been designed and conducted by using different powder feeding nozzles-a three-jet and a coaxial powder feeding nozzle-since the powder stream is mainly determined by the geometry of the powder feeding nozzle. After the deposition trials, metallographic analysis of the samples has been performed. The laser intensity distribution (LID) and the powder stream intensity distribution (PID) have been characterized, based on which the processes have been simulated. Finally, for verifying and correcting the used models for the simulation, the simulated results have been compared with the experimental results. Through the conducted work, suitable boundary conditions for simulating the process with different powder streams has been determined, and the effects of the powder stream on the process have also been determined. For a LMD process with a three-jet nozzle a substantial part of the powder particles that hit the melt pool surface are rebounded; for a LMD process with a coaxial nozzle almost all the particles are caught in the melt pool. This is due to the different particle velocities achieved with the two different nozzles. Moreover, the powder stream affects the heat exchange between the heated particles and the melt pool: a surface boundary condition applies for a powder stream with lower particle velocities, in the experiment provided by a three-jet nozzle, and a volumetric boundary condition applies for a powder stream with higher particle velocities, provided by a coaxial nozzle.

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Section: Introductionmentioning

confidence: 99%

The Influence of the Powder Stream on High-Deposition-Rate Laser Metal Deposition with Inconel 718

Chen

Pirch

Gasser

et al. 2017

Metals

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“…The kinematic constraints with laser metal deposition technique consists in keeping the translation speed constant and identifying the best tilt of the laser head with respect to the underlying surface. [27][28][29][30] highlight that the process is feasible, although not optimal, for a large range of relative orientations between the deposition axis and the line perpendicular to the surface. Thus, it is possible to optimize the trajectory in order to keep the tilt angle as small as possible and respecting also kinodynamic constraints at the same time.…”

Section: Introductionmentioning

confidence: 99%

Optimal Robot Motion Planning of Redundant Robots in Machining and Additive Manufacturing Applications

et al. 2019

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The paper deals with the generation of optimal trajectories for industrial robots in machining and additive manufacturing applications. The proposed method uses an Ant Colony algorithm to solve a kinodynamic motion planning problem. It exploits the kinematic redundancy that is often present in these applications to optimize the execution of trajectory. At the same time, the robot kinematics and dynamics constraints are respected and robot collisions are avoided. To reduce the computational burden, the task workspace is discretized enabling the use of efficient network solver based on Ant Colony theory. The proposed method is validated in robotic milling and additive manufacturing real-world scenarios.

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“…High-strength aluminum alloy is widely used in high speed trains, aerospace, military industry and high-end equipment fields by virtue of its high strength, high corrosion resistance and other beneficial combination properties [1,2]. Laser processing is a promising technology that has been used widely in the material processing field [3][4][5][6][7][8][9]. Laser welding is also widely used in various material processing.…”

Section: Introductionmentioning

confidence: 99%

Weld Formation in Laser Hot-Wire Welding of 7075 Aluminum Alloy

Wei

Xiao

et al. 2018

Metals

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The laser hot-wire welding process was adopted to weld 7075 high-strength aluminum alloy. The influence laws of parameters on the weld formation were analyzed during laser hot-wire welding, and the microstructure characteristics and mechanical properties of welds were analyzed. The results showed that the parameters whose significance of influence on weld formation as ranked from high to low were laser power, current, gap width, welding speed and wire feeding rate. With the increase of wire temperature, the weld formation quality became better initially and then worse. Under the condition of optimized parameters, good weld formation could be obtained. The weld zone had a fine grain microstructure, and was in casting state consisted of dendritic crystal and equiaxed crystal. The heat affected zone mainly consisted of columnar crystal. The microhardness decreased gradually from base metal to heat affected zone then to weld zone. The tensile fracture of weld specimen occurred at the weld zone, and was in the ductile fracture state. The tensile strength of weld joint was 206 MPa and was 64.2% of base metal strength. aluminum alloy has high thermal conductivity and high reflectivity. Therefore, higher laser energy shall be introduced to realize the welding. However, during welding with much higher laser energy, the welding keyhole and molten pool fluctuate more frequently, which will cause an unstable welding process. The closure, collapse and necking of keyhole can easily cause more bubbles in molten pool, inducing poor welding quality. Therefore, improving the stability of dynamic behaviors of the keyhole and molten pool can not only reduce the generation of porosities, but also obtain better welding quality [18][19][20][21].Laser hot-wire welding is a multi-heat source welding method combining a laser heat source and current heating welding wire [22]. The welding wire will be preheated by the current during the welding process, which can reduce the dependency of the welding wire on the laser heat source and enhance the utilization efficiency of the laser to melt the base metal. The preheating temperature of welding wire can be accurately controlled through adjusting the current, thus the feeding stability of the welding wire can be controlled and good welding quality can be obtained. Wen et al.[23] studied the transition behavior of welding wire in the laser hot-wire welding process. Different transition behaviors of welding wire were observed under different technological conditions through high-speed camera. At different preheating temperatures of welding wire, the welding wire had three transition modes: Dropping transition, fusing and broke transition and continuous transition. Good weld formation and a stable welding process could be obtained when the welding wire was in continuous transition mode. Ohnishi et al.[24] studied the high-power laser hot wire welding of high-strength steel plate. The results showed that the preheating of wire and sufficient laser power can produce a fully penetrated keyhole, which ...

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Improvement of strategies and parameters for multi-axis laser cladding operations

Cited by 83 publications

References 14 publications

The Influence of the Powder Stream on High-Deposition-Rate Laser Metal Deposition with Inconel 718

The Influence of the Powder Stream on High-Deposition-Rate Laser Metal Deposition with Inconel 718

Optimal Robot Motion Planning of Redundant Robots in Machining and Additive Manufacturing Applications

Weld Formation in Laser Hot-Wire Welding of 7075 Aluminum Alloy

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