Almir Heralić, University West Laser Metal Deposition: Supporting technology for manufacture of complex structures in the aero industry Almir Heralić, Anna-Karin Christiansson, Mattias Ottosson, University West Torbjörn Norlander, Peter Jonsson, Börje Nordin, Volvo Aero FLUD - VINNOVA

Laser Metal Deposition Almir Heralić, University West What is Metal Deposition? Metal deposition is an additive process that joins metal beads side-by-side layer-by-layer according to predefined paths. Beads are formed by melting metal wire (or powder) using a heat source, e.g. a laser or other welding equipment

Laser Metal Deposition Almir Heralić, University West

Laser Metal Deposition Almir Heralić, University West

Laser Metal Deposition Almir Heralić, University West Metal deposition example Deposition movie

Laser Metal Deposition Almir Heralić, University West Close-up view of the melt pool

Laser Metal Deposition Almir Heralić, University West Some applications  Prototyping  New manufacturing –Fabrication –Shape modification  High-value component repair or modification  …

Laser Metal Deposition Almir Heralić, University West Fabrication Welding, forging, machining, casting, metal deposition, sheet metal forming

Laser Metal Deposition Almir Heralić, University West Fabrication – example Ti-6Al-4V sheet metal + welding LMD (weld prep)LMD machining + welding casting

Laser Metal Deposition Almir Heralić, University West  Standard welding cell rather than specially made high-cost equipment  Laser heat source implies low heat input  Metal wire instead of powder  A 6-axis robot offers flexibility  Reduction in waste material and energy  Potential for cost efficiency and shorter lead times Process advantages - LMD

Laser Metal Deposition Almir Heralić, University West  Demanding from a sensor and measurement point of view  The process is not fully understood  The use of wire imposes certain limitations ... Identified difficulties

Laser Metal Deposition Almir Heralić, University West Process related difficulties Several process parameters need careful tuning to obtain a stable process. For example: Laser power/wire speed ratio Wire tip position relative the weld pool Estimated bead height

Laser Metal Deposition Almir Heralić, University West Process related difficulties Incorrect process parameters usually lead to: formation of droplets gives irregular deposition insufficient melting of the wire can lead to lack of fusion

Laser Metal Deposition Almir Heralić, University West Laser power/wire speed vs. weld quality

Laser Metal Deposition Almir Heralić, University West Results – manual control Common errors without feedback Manual control with feedback

Laser Metal Deposition Almir Heralić, University West Automation of LMD

Laser Metal Deposition Almir Heralić, University West Welding tool - sensor configuration

Laser Metal Deposition Almir Heralić, University West Feedforward height control

Laser Metal Deposition Almir Heralić, University West PI-control of bead width

Laser Metal Deposition Almir Heralić, University West Results Developed an LMD cell with a sensor- and measurement system Stable process ensured, manual/automatic control Good dimensional accuracy Reduced risk for lack of fusion defects

Laser Metal Deposition Almir Heralić, University West University West / industrial partners: Increase the knowledge about the LMD process, e.g. temperature influence on the geometrical and mechanical properties of the deposited parts. Develop Off-Line Programming tools. Manufacturing industry: Work towards industrialization of the LMD process Future work