Laser casting and laser clad-casting: New processes for rapid prototyping and production

Abstract

This paper presents preliminary experimental results from two new processes: 1. Laser casting involves a process similar to blown powder laser cladding but the final product is not joined to the substrate. The substrate surface therefore acts as a mould in a laser casting process and the eventual casting retains the topological features of the substrate. 2. Laser clad-casting involves the production of clad tracks which are welded as usual to a substrate but which are laid down between machined copper blocks. The eventual clad track therefore has its cross sectional profile determined by the blocks which are removed after completion of the cladding process. In this way clad tracks with large depth to width ratios can be achieved with pre determinated cross sections. This paper presents preliminary experimental results from two new processes: 1. Laser casting involves a process similar to blown powder laser cladding but the final product is not joined to the substrate. The substrate surface therefore acts as a mould in a laser casting process and the eventual casting retains the topological features of the substrate. 2. Laser clad-casting involves the production of clad tracks which are welded as usual to a substrate but which are laid down between machined copper blocks. The eventual clad track therefore has its cross sectional profile determined by the blocks which are removed after completion of the cladding process. In this way clad tracks with large depth to width ratios can be achieved with pre determinated cross sections.