Almir Heralić, University West Laser Metal Deposition: Supporting technology for manufacture of complex structures in the aero industry Almir Heralić, Anna-Karin Christiansson, Mattias Ottosson, University West Torbjörn Norlander, Peter Jonsson, Börje Nordin, Volvo Aero FLUD - VINNOVA
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Almir Heralić, Anna-Karin Christiansson, Mattias Ottosson, University West
Laser Metal Deposition: Supporting technology for manufacture of complex structures in the aero industry. Almir Heralić, Anna-Karin Christiansson, Mattias Ottosson, University West Torbjörn Norlander, Peter Jonsson, Börje Nordin, Volvo Aero. FLUD - VINNOVA. What is Metal Deposition?. - PowerPoint PPT Presentation
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Almir Heralić, University West
Laser Metal Deposition: Supporting technology for manufacture of complex structures in the aero industry
Almir Heralić, Anna-Karin Christiansson, Mattias Ottosson, University West
Torbjörn Norlander, Peter Jonsson, Börje Nordin, Volvo Aero
FLUD - VINNOVA
Laser Metal Deposition
Almir Heralić, University West
What is Metal Deposition?
Metal deposition is an additiveprocess that joins metal beads
• side-by-side
• layer-by-layer
according to predefined paths.
Beads are formed by melting metal wire (or powder) using a heat source, e.g. a laser or other welding equipment
Laser Metal Deposition
Almir Heralić, University West
Laser Metal Deposition
Almir Heralić, University West
Laser Metal Deposition
Almir Heralić, University West
Metal deposition example
Deposition movie
Laser Metal Deposition
Almir Heralić, University West
Close-up view of the melt pool
Laser Metal Deposition
Almir Heralić, University West
Some applications
Prototyping
New manufacturing – Fabrication– Shape modification
High-value component repair or modification
…
Laser Metal Deposition
Almir Heralić, University West
Fabrication
Welding, forging, machining, casting, metal deposition, sheet metal forming
Laser Metal Deposition
Almir Heralić, University West
Fabrication – example Ti-6Al-4V
sheet metal + welding
LMD (weld prep)LMD
machining + welding
casting
Laser Metal Deposition
Almir Heralić, University West
Standard welding cell rather than specially
made high-cost equipment
Laser heat source implies low heat input
Metal wire instead of powder
A 6-axis robot offers flexibility
Reduction in waste material and energy
Potential for cost efficiency and shorter lead
times
Process advantages - LMD
Laser Metal Deposition
Almir Heralić, University West
Demanding from a sensor and
measurement point of view
The process is not fully understood
The use of wire imposes certain limitations
...
Identified difficulties
Laser Metal Deposition
Almir Heralić, University West
Process related difficulties
Several process parameters need careful tuning to obtain a stable process.
For example:
•Laser power/wire speed ratio
•Wire tip position relative the weld pool
•Estimated bead height
Laser Metal Deposition
Almir Heralić, University West
Process related difficulties
Incorrect process parameters usually lead to:
• formation of droplets
gives irregular deposition
• insufficient melting of the wire
can lead to lack of fusion
Laser Metal Deposition
Almir Heralić, University West
Laser power/wire speed vs. weld quality
Laser Metal Deposition
Almir Heralić, University West
Results – manual control
Common errors without feedback
Manual control with feedback
Laser Metal Deposition
Almir Heralić, University West
Automation of LMD
Laser Metal Deposition
Almir Heralić, University West
Welding tool - sensor configuration
Laser Metal Deposition
Almir Heralić, University West
Feedforward height control
Laser Metal Deposition
Almir Heralić, University West
PI-control of bead width
Laser Metal Deposition
Almir Heralić, University West
Results
• Developed an LMD cell with a sensor- and measurement system
• Stable process ensured, manual/automatic control
• Good dimensional accuracy
• Reduced risk for lack of fusion defects
Laser Metal Deposition
Almir Heralić, University West
University West / industrial partners:
Increase the knowledge about the LMD process, e.g.
temperature influence on the geometrical and mechanical
properties of the deposited parts. Develop Off-Line