Abstract
Hybrid manufacturing processes are known for combining the advantages of additive manufacturing and more traditional manufacturing processes such as machining to create components of complex geometry while minimising material waste. The trend towards lightweight design, especially in view of e-mobility, gives aluminium materials an important role to play. This study examines the use of aluminium alloys in laser metal wire deposition (LMWD) processes with subsequent subtractive machining, which is considerably more difficult due to the different process-related influences. The investigations are focussed on the influence of the differently controlled laser power on the shape accuracy, the microstructure, and the hardness of the AlMg5 test components after the LMWD process with subsequent subtractive machining by turning. The long-term goal of the investigations is to increase the stability of the hybrid production process of AlMg5 components with defined dimensional accuracy and mechanical properties.
Highlights
Due to their suitability for lightweight design, aluminium components are widely used in many areas such as the automotive and aerospace industries
This study examines the influence of a laser power control during the laser cladding process on the quality of the test components as well as the influence of subsequent machining
The adjustment of the laser power carried out at Institut für Strahlwerkzeuge (IFSW) to suppress process overheating had a strong influence on the shape accuracy of the additive component
Summary
Due to their suitability for lightweight design, aluminium components are widely used in many areas such as the automotive and aerospace industries. These problems do not arise as the aluminium components can be directly produced without forming tools and close to the final contour [6,7,8]. The International Journal of Advanced Manufacturing Technology decisively influenced by the laser power and by the power absorbed in the material. One of these DED processes that uses wire as filler material is laser metal wire deposition (LMWD). The test components produced by the laser cladding process were evaluated based on form accuracy, surface roughness, microstructure, and hardness before and after subtractive machining
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