Abstract
Directed metal deposition by means of laser beam is investigated in this article. The process is receiving increasingly interest in the frame of additive manufacturing to the purpose of maintenance, repair and overhaul of condemned products when severe conditions hindering the working order have been experienced. Minimal distortion, reduced heat-affected zones and better surface quality are benefited in comparison with conventional techniques. Namely, metal feeding of 2024 aluminium powder is considered to produce clad traces on 2024 aluminium plates, aiming to give grounds for repairing damaged real components using materials with same or similar features with respect to the parent metal. A fibre-delivered disc laser and a three-way feeding nozzle are used. The responses are discussed in terms of geometry, microstructure and microhardness both in the fusion zone and in the heat-affected zone; the optimization is conducted via desirability functions, based on proper technical constraints upon numerical modelling. Reparation of real parts, where cracks are machined to produce V-grooves to be filled, is aimed.
Highlights
A number of innovative technologies are offered in the literature to the purpose of additive manufacturing to keep parts and devices in working order when local manufacturing imperfections or demanding conditions of temperature, wear and mechanical stresses have been experienced.[1]
Since part replacement would result in increased costs for any component of complex geometry, mainly in aerospace and automotive,[2,3] proper actions are required to the purpose of cost saving
Usual international or customer standards for quality in laser welding[30] are borrowed, since no specific regulations are available at present for directed metal deposition (DMD)
Summary
A number of innovative technologies are offered in the literature to the purpose of additive manufacturing to keep parts and devices in working order when local manufacturing imperfections or demanding conditions of temperature, wear and mechanical stresses have been experienced.[1] Since part replacement would result in increased costs for any component of complex geometry, mainly in aerospace and automotive,[2,3] proper actions are required to the purpose of cost saving. Since metal impinging the pool is fed concurrently (i.e. in singlestage processing) in the form of wire or loose powder,[5] a deposited metal trace results, with metallurgical bonding to the substrate thanks to fusion and diffusion. Side overlapping of the individual laser traces is required to process wider surfaces on 3D complex geometries.
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