Additive laser manufacturing of small metallic components by laser micro-cladding

Abstract

Rapid manufacturing techniques have allowed to reduce the time to market of complex parts. Indeed, these additive processes do not need specific tools design and can be produced directly from CAD files.Thanks to its long experience in the field of laser processing, IREPA LASER has developed tools adapted to the rapid manufacturing of small metallic parts based on its patent on a coaxial powder cladding nozzle. The process consists in the deposition of melted powders in a melt pool in order to build 3D part or to cover small surfaces with metallic layers with specific properties. The powder filler material is injected coaxially into a laser beam. Thus the energy input is partly used to melt the filler material, but also to melt a fine layer of the substrate. This coaxial configuration of the nozzle allows for the processing of low size structures using layer-by-layer build in all directions. With computational models and cladding experiments, this new process allows the additive construction of very dense parts with fine microstructure. The process was validated with a fibre laser, titanium alloy, and stainless steel powders. With the assistance of a new specific software, thin walls of 0,6mm width and 3D shapes (aeronautic parts for example) were obtained with less than 200W and a high powder deposition efficiency (>=50%). This process is promising for the manufacturing of mechanical components, or the addition of new shapes on existing parts.Rapid manufacturing techniques have allowed to reduce the time to market of complex parts. Indeed, these additive processes do not need specific tools design and can be produced directly from CAD files.Thanks to its long experience in the field of laser processing, IREPA LASER has developed tools adapted to the rapid manufacturing of small metallic parts based on its patent on a coaxial powder cladding nozzle. The process consists in the deposition of melted powders in a melt pool in order to build 3D part or to cover small surfaces with metallic layers with specific properties. The powder filler material is injected coaxially into a laser beam. Thus the energy input is partly used to melt the filler material, but also to melt a fine layer of the substrate. This coaxial configuration of the nozzle allows for the processing of low size structures using layer-by-layer build in all directions. With computational models and cladding experiments, this new process allows the additive construction of very dense ...