Abstract
Hybrid manufacturing processes that combine additive and machining operations are gaining relevance in modern industry thanks to the capability of building complex parts with minimal material and, many times, with process time reduction. Besides, as the additive and subtractive operations are carried out in the same machine, without moving the part, dead times are reduced and higher accuracies are achieved. However, it is not clear whether the direct material deposition after the machining operation is possible or intermediate cleaning stages are required because of the possible presence of residual cutting fluids. Therefore, different Laser Metal Deposition (LMD) tests are performed on a part impregnated with cutting fluid, both directly and after the removal of the coolant by techniques such as laser vaporizing and air blasting. The present work studies the influence of the cutting fluid in the LMD process and the quality of the resulting part. Resulting porosity is evaluated and it is concluded that if the part surface is not properly clean after the machining operation, deficient clad quality can be obtained in the subsequent laser additive operation.
Highlights
Modern industry is heading to the “factory in the machine” concept, where hybrid machines that combine additive and machining operations are gaining relevance thanks to the fact that they enable to build ready to use products in a single machine [1,2]
The process is based on the generation of a melt pool on the surface of the substrate, whereas filler material is simultaneously added in the form of powder or wire [5]
Results obtained after the evaluation of the cross sections of the different
Summary
Modern industry is heading to the “factory in the machine” concept, where hybrid machines that combine additive and machining operations are gaining relevance thanks to the fact that they enable to build ready to use products in a single machine [1,2]. The integration of laser-based additive and machining processes results in a combined process that strengthens both processes advantages [3] and process time reduction [4]. Evidence of this are the hybrid machine solutions developed by the most advanced machine tool companies, such as DMG Mori, Mazak, Okuma and many other smaller but leading companies such as Ibarmia. The process is based on the generation of a melt pool on the surface of the substrate, whereas filler material is simultaneously added in the form of powder or wire [5]. Line by line, coating layers are generated and, by means of overlapping the subsequent layers, the desired final geometry is obtained
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