Laser Engineered Net Shaping (LENS)
Post on 10-Oct-2015
21 Views
Preview:
DESCRIPTION
Transcript
developedatSandiaNationalLaboratory NewMexico USAdevelopedatSandiaNationalLaboratory,NewMexico,USAandcommercialised byOptomec,USA
presented byPS h IITKhPSaha IITKharagpur
11/11/2013 1PSaha
Motivationbehinddevelopmentp Fullydense functionalmetallic components. Pickand placematerialcomposition totailorp plocalizedmaterialcharacteristics withinapart.
Repairandoverhaul technologiestoextendthelifeofcomponentsinagingaircraft ship vehicles andweaponcomponentsinagingaircraft,ship,vehicles,andweaponsystems. Convetional repairtechniquessuchasMIGorTIGweldinginduce
excessiveheatandalargeHEATAFFECTEDZONE(HAZ)excessiveheatandalargeHEATAFFECTEDZONE(HAZ)destroyingusefulnessofthepart.
Highcostofscrappingormaintainingcriticalparts,especially,whendrawingsdonotexist,whendrawingsdonotexist,
Partsdeemednonrepairableduringtheirrepairprocess Fabricate sparepartasandwhenrequiredfromitsoriginalCADdesign ratherthankeepingahugeinventoryoriginalCADdesign,ratherthankeepingahugeinventory.
11/11/2013 2PSaha
Schematic of the LENS processSchematicoftheLENSprocess
11/11/2013 3PSaha
LENSProcessstepsp Acomponentisfabricatedbycreatingamoltenpoolthroughfocusingalaserbeam ontoasubstrate.
Metalpowder particlesaresimultaneouslyinjectedintothepooltoaddmaterial.
Usingcomputercontrol thesubstrateismovedbeneath Usingcomputercontrol,thesubstrateismovedbeneaththelaserbeam intheXYplane,depositingathincrosssectionofpredeterminedCADgeneratedgeometry.Af d i i f l h d i i h d Afterdepositionofalayer,thedepositionhead(consistingofapowderdeliverynozzleandfocusinglensassembly)isincrementedinthepositiveZdirection,ll i i f h l f h allowinggenerationofthenextlayerofthepart.
Depositionoflayersisrepeateduntilthedesiredthreedimensionalcomponenthasbeenlayeradditivelyformed.dimensionalcomponenthasbeenlayeradditivelyformed.
11/11/2013 4PSaha
Powderdeliverynozzle
11/11/2013 5PSaha
ConstructionofthinwalledstructurewithfournozzleConstructionofthin walledstructurewithfournozzlepowderdeliverysystem
11/11/2013 6PSaha
NdYAGlaservs.CO2 laser Sinceitisundesirable
tovaporizemateial asitisdeposited opticalitisdeposited,opticalabsorptionofmaterialiscriticalforeffectiveutilizationoflaserenergy.
Withtheexceptionofcopper allofthecopper,alloftheelementalmetalsshowninthegraphhavesignificantlyg yabsorptionattheNdYAGlaserwavelengthascomparedtoCO2laserlaser.
Fiberlaserat1070nmhassimilarabsorptionasthatofNdYAGlaser11/11/2013 7PSaha
CapabilitiesofLENSprocessp p Abilitytobuildfullydense shapes Closedloopcontrol ofprocessforaccuratepartfabrication
Abilit t t il dd iti t t f t i f d Abilitytotailoreddeposition parameterstofeaturesizeforspeed,accuracy,andpropertycontrol
Compositeandfunctionallygraded materialdeposition ThreeaxisandfouraxissystemsforcomplexpartfabricationThree axisandfour axissystemsforcomplexpartfabrication Withthistechnology,materialsthateithercannotbe cast andthermo
mechanicallyprocessed,orthatcannotbeconsolidated successfullybypowdermetallurgy,canbeformed.
d f l h l d l l ll Widevarietyofmaterials that,atminimum,include:stainlesssteelalloys(316,304L,309,174),maraging steel (M300),nickelbasedsuperalloys(Incodesignations625,600,718,690),toolsteel alloys(H13),titaniumalloy(6Al4V),andotherspecialtymaterials( 4 ), p y
Highcoolingrate(102 103 K/s)leadsto finermicrostructure Mechanicalproperties similarorbetter thantraditionalprocessing
methods
11/11/2013 8PSaha
VaryingCompositiony g p Multiplepowderdeliverynozzlesarecapableofvaryinglocalcompositionvaryinglocalcomposition.
11/11/2013 9PSaha
Different Build Styles with VaryingDifferentBuildStyleswithVaryingCompositionpDependingonthedesigncriterionofapart,materialcompositioninLENScanbevariedthroughcompositioninLENScanbevariedthrough compositematerialdeposition thepowdercompositionremainsconstantfordistinctbuildpregions,and
functionallygradedmaterial(FGM) depositionthepowdercompositioniscontinuouslychanging
FGMrequiresaheavierinteraction betweenthepowderfeedercontroller andtheLENSmotioncontrollercontroller.
11/11/2013 10PSaha
(a)AcompositeconsistsofdistinctregionsofAandB (b)CompositesmaybeconstructedbyfirstdrawingallofregionAandthen (c)drawingallofregionB,allowingpowderfeederstobereconfiguredbetweencompositions. (d)FGMsrequirethepowdertobecontinuallyvariedthroughoutthebuild (d)FGMsrequirethepowdertobecontinuallyvariedthroughoutthebuild. (e)eachdepositionvectorinanFGMbuildwillhaveauniquepowderfeederprofile.
11/11/2013 11PSaha
PowderFeederCharacterization
PowderFeederSetUp(Feeder,Screw,Feedlinelengthetc.)
Powderistransportedfromapowderhoppertothegasstream Ascrewfeeddevice usesanopenthreadedshafttometerpowderintoan
argoncarriergasstreamargoncarriergasstream Asinglecarriergaslineisdividedintotwodistinctflows,passedthrough
thefeedersandthenrecombinedintoasingleline. Mixingofthetwopowders occursnaturallyintherejoinedargonstreamg p y j g
11/11/2013 12PSaha
Forcomposites,thechiefcriterionforsuccessfuldepositionisthatthepowderfeedersprovidethedesireddepositionisthatthepowderfeedersprovidethedesiredpowdercompositionforagivenperiodoftime.Thesystemcaneffectivelypauselongenough forpowdery p g g pcompositionstobealteredandreachsteadystate.
ForFGMs,thereisasignificanttimelagbetweenaskingforagivencompositionandwhenthatcompositionisactuallyi j di h l lb i i l H injectedintothemoltenpoolbecomescritical.Hencethoroughcharacterizationofpowderfeederisneeded.
11/11/2013 13PSaha
OPTOMECs FOPTOMEC sLENS850SYSTEM
Features 1100Wcontinuous
NdYAGlaserd G ase Fiberopticbeam
delivery 18x18x42build 18 x18 x42 build
envelop 4th and5th axis:rotary
andtiltstagesandtiltstages Controlargon
atmospherewithoxygensensoroxygensensor
FilteringsystemforparticulatecontrolCCD i i CCDvision
Glovebox Power220V3phasePower220V3phase
100A11/11/2013 14PSaha
S 8 0 ifi iLENS850systemspecifications
11/11/2013 15PSaha
Materials deposited using the LENSMaterialsdepositedusingtheLENSProcess
11/11/2013 16PSaha
Measured tensile values for LENS vMeasuredtensilevaluesforLENSv.forged/annealedspecimensg / p
11/11/2013 17PSaha
ApplicationsofLENSpp ToolingapplicationsforInjectionMoldToolingandDie
Casting whereLENS'canimprovecycletimesby50%andg p y y 5extendmoldlife. Conformalcoolingchannelsarepossible.
RepairandOverhaul applicationsduetosmallHeatAffectedZone(HAZ) allowingforhigheryieldandsuperiorpartrepairsZone(HAZ),allowingforhigheryieldandsuperiorpartrepairs.
Functional"PrototypingandSmallLotManufacturingmadepossibleduetoproducingfullydensemetalpartswith
di h i l i (hi h h&d ili ) outstandingmechanicalproperties(highstrength&ductility),notfoundwithRapidPrototypingsystems
MaterialResearch :improvementofpropertiesinexistingp p p galloysandcomposites;developmentofnewalloysandcomposites.LENS'abilitytoprovidemultiplematerialgradientdepositionoffersuniquematerialresearchoptionsdepositionoffersuniquematerialresearchoptions.
11/11/2013 18PSaha
Applicationspp
Building Up of Turbine Blade Finished TurbineBuilding Up of Turbine Blade by LENS
Finished Turbine Blade
11/11/2013 19PSaha
Applicationspp
H13 Tooling
Thin Walled Housing
H13 Tooling
Impeller
11/11/2013 20PSaha
Six Inch Tall Thin Walled Part Substrate Included in Part
Housing Finished Housing11/11/2013 21PSaha
ToolingPartsbyLENSProcessg y
Injection Molding Injection Mold CavityInjection Molding Core
Injection Mold Cavity
Conformal Cooling Channel
11/11/2013 22PSaha
ToolingPartsbyLENSProcessg y
Trimming DieTrimming Die
11/11/2013 23PSaha
Insuchaninjectionmold,ah d l lhardtoolsteelmaybeselectivelyplacedinregionsh i whereexcessive
wearwouldbeanissue,yetthebulkofthemoldcouldofthemoldcouldbemadeofamaterialwithabettercoefficientbettercoefficientofthermalconduction.)
Injectionmoldingdies(coreandcavity,CADimageandFinalj g ( y, gfabricatedparts)withcopperchillerblockandthreedimensionalconformalcoolingchannel.11/11/2013 24PSaha
11/11/2013 25PSaha
11/11/2013 26PSaha
ProcessessimilartoLENSProcess
11/11/2013 27PSaha
C ll d M l B ild UP (CMB)ControlledMetalBuildUP(CMB)(Developed at Fraunhofer IPT, Aachen Germany)(DevelopedatFraunhofer IPT,AachenGermany)
11/11/2013 28PSaha
Di M l D i i (DMD)DirectMetalDeposition(DMD)(Developed at University of Michigan, USA)(DevelopedatUniversityofMichigan,USA)
11/11/2013 29PSaha
Comparison of Direct MetalComparisonofDirectMetalFreeformProcesses
Process Deposition Type Accuracy Horizontal
Layer Thickness Deposition Rate Materials
SLS L i i Hi h N/A N/A S lSLS Laser sintering High N/A N/A Steel, copper, Solder
SDM Droplet based and cladding
N/A, Machined finish
Variable 30g/min Stainless steel, INVAR
Welding Welding 0.2-0.5 mm Up to 50 mm N/A, High Steels, Numerous
Droplet based freeform fabr
Droplet based N/A N/A 25-150 m dia. droplets
Bi-Sn
LENS Cladding 0.02mm, Z: 0 4mm
0.13-0.38 mm N/A, Low SS, Ti alloys, Numerous0.4mm Numerous
DLF Cladding 0.075-0.125 mm 0.075-0.125 mm 1-2g/min SS, P20, Numerous
DMD at Michigan Cladding N/A 0 254 mm 0 1 4 1 cm3/min H13 AlDMD at Michigan Cladding N/A 0.254 mm 0.1-4.1 cm3/min H13, Al, Numerous
11/11/2013 30PSaha
top related