Rapid fabrication of functionally gradient material parts by laser beam

Abstract

A customized laser deposition system is built for the rapid fabrication of Functionally Gradient Material (FGM) parts. Up to four novel powder-feeders are integrated into the system to achieve precise and steady delivery of powder with any compositional combinations. An infrared image sensing system and a laser vision system are used to monitor and control the manufacturing process in real time. By optimizing the laser processing conditions, three WC-(NiSIB alloy)/H13 FGM samples, i.e. a single-bead-wide wall, a solid cylinder and a friction stir welding tool, are successfully produced. The analysis of the samples exhibits the expected compositional and micro-structural gradients. The mechanical properties of the functionally gradient material are evaluated and the produced FGM friction stir welding tool is tested by welding aluminum alloy.A customized laser deposition system is built for the rapid fabrication of Functionally Gradient Material (FGM) parts. Up to four novel powder-feeders are integrated into the system to achieve precise and steady delivery of powder with any compositional combinations. An infrared image sensing system and a laser vision system are used to monitor and control the manufacturing process in real time. By optimizing the laser processing conditions, three WC-(NiSIB alloy)/H13 FGM samples, i.e. a single-bead-wide wall, a solid cylinder and a friction stir welding tool, are successfully produced. The analysis of the samples exhibits the expected compositional and micro-structural gradients. The mechanical properties of the functionally gradient material are evaluated and the produced FGM friction stir welding tool is tested by welding aluminum alloy.