Investigation of laser consolidation process for manufacturing structural components for advanced robotic mechatronics system (ARMS)

Abstract

Laser consolidation (LC) is a computer-aided manufacturing process that builds a complete part or features on an existing part, based on a CAD model, through the melting of injected metallic powder by a laser beam without the use of moulds or dies. Advanced Robotic Mechatronics System (ARMS) project was initiated by MD Robotics and supported by the Canadian Space Agency’s Space Technology Development Program. The main objective of this project was to investigate the use of enabling and emerging technologies for the design and manufacture of the next generation space robotic arms. The laser consolidation process was evaluated as a rapid functional prototype manufacturing process for the production of structural components using Ti-6Al-4V alloy. The LC Ti-6Al-4V components are metallurgically sound and show excellent mechanical properties. The LC process is particularly suitable for the manufacturing of components with complicated internal features or complex components consisting of multiple parts requiring to be integrated into one final assembly that are often very difficult or even impossible to produce using conventional manufacturing methods. The ARMS prototype robotic joint has been successfully assembled for demonstration at MDR and all structural components were manufactured from LC Ti-6Al-4V. In addition, the LC process also proved to be an excellent tool for the repair of parts damaged during the machining operations. The paper also discusses potential benefits and application of LC technology for in-space manufacturing.Laser consolidation (LC) is a computer-aided manufacturing process that builds a complete part or features on an existing part, based on a CAD model, through the melting of injected metallic powder by a laser beam without the use of moulds or dies. Advanced Robotic Mechatronics System (ARMS) project was initiated by MD Robotics and supported by the Canadian Space Agency’s Space Technology Development Program. The main objective of this project was to investigate the use of enabling and emerging technologies for the design and manufacture of the next generation space robotic arms. The laser consolidation process was evaluated as a rapid functional prototype manufacturing process for the production of structural components using Ti-6Al-4V alloy. The LC Ti-6Al-4V components are metallurgically sound and show excellent mechanical properties. The LC process is particularly suitable for the manufacturing of components with complicated internal features or complex components consisting of multiple parts requirin...