Abstract
Wire-based Laser Metal Deposition (LMD-w) is a suitable manufacturing technology for a wide range of applications such as repairing, coating, or additive manufacturing. Employing a pulsed wave (pw) laser additionally to the continuous wave (cw) process laser has several positive effects on the LMD process stability. The pw-plasma has an influence on the cw-absorption and thus the temperature distribution in the workpiece. In this article, several experiments are described aiming to characterize the heat input during dual beam LMD. In the first setup, small aluminum and steel disks are heated up either by only cw or by combined cw and pw radiation. The absorbed energy is then determined by dropping the samples into water at ambient temperature and measuring the water’s temperature rise. In a second experiment, the temperature distribution in the deposition zone under real process conditions is examined by two-color pyrometer measurements. According to the results, the pw plasma leads to an increase of the effective absorption coefficient by more than 20%. The aim of this work is to achieve a deeper understanding of the physical phenomena acting during dual beam LMD and to deploy them selectively for a better and more flexible process control.
Highlights
Since Laser Metal Deposition with wire (LMD-w) combines comparatively high deposition rates with a feedstock material which can be handled in a quick and safe way without contaminations, it is a suitable technology for a wide range of applications [2]
The effectiveabsorption absorption coefficients were determined by processing laser processing small samples metallic which were subsequently dropped into water at ambient temperature
The present work reveals important results concerning the impact of the pulsed laser-induced plasma on the absorption of process energy and the workpiece temperature during two-beam wire-based Laser Metal Deposition (LMD-w)
Summary
They can be classified either by the properties of the filler material (wire, powder, and flakes) or by the form of energy supply (e.g., electric arc, laser, and gas flame). LMD processes are suitable to be automated and can be accompanied by different sensor systems such as in-situ optical scanning of the welding bead surface or temperature monitoring. This allows the generation of data for the setup of a Digital Twin which helps to make production more transparent and reliable [3,4]
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