Technology Innovation for the Manual Laser Cladding of High-Alloy Tool Steels

Jonas Kimme,Verena Kräusel,Josephine Zeisig,Alexander Fröhlich

doi:10.3390/met11111820

Jonas Kimme, Verena Kräusel + Show 2 more

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https://doi.org/10.3390/met11111820

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Abstract

This paper presents the development and successful application of an inductive preheating system running simultaneously with the manual laser cladding process in order to enable the repair of high-alloy tool steels having a highly limited weldability. In this study, the design and optimization of a suitable inductor as well as the analysis of the welding process were carried out by means of FE-simulation in order to generate material deposition without imperfections. Parameter variation studies were conducted while parallel modifying the generator power resulting in different preheating temperatures. These examinations showed that by using appropriate process parameters and an inductive preheating temperature of 200 °C, crack- and pore-free deposition layers could be produced on the commercial high-alloyed PM steel Elmax. This result can be explained by FE-simulation demonstrating that the cooling rate was halved in the weld and in the heat-affected zone. In conclusion, this study shows the high potential of the developed technical innovation for the manual laser cladding of high-performance tools.

Highlights

Tools, which are used for injection molding, forming or cutting, are subject to a high level of wear load during use
A direct comparison with initial deposition welds (Figure 2) without preheating shows that the tendency to cracking by using the same laser parameters was significantly reduced by the tailored inductive preheating
It can be seen that preheating approximately reduces the cooling rate of the weld metal and in the heat-affected zone (HAZ) of the substrate around the weld by half

Summary

Introduction

Tools, which are used for injection molding, forming or cutting, are subject to a high level of wear load during use. This often leads to their failure and, to a downtime in production. The increasing processing of high-strength alloys and composite materials for the automotive industry, mechanical and plant engineering or power engineering results in a reduced tool life. For these cases, laser deposition welding has proven to be a suitable process and occupies a key position in modern toolmaking [1]. A welding process is used to apply material layer by layer onto the substrate

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