1. EWI’s Laser Equipment 15-kW IPG Fiber Laser 4-way beam switch
15-kW Laser

2. Laser Optics for Broad Coverage
Off-the-shelf integrated focusing optic
Integrator lens with 6- × 8-mm rectangular spot
Beam shape on thermoplastic burn block
Integrator Lens
Beam shape on burn paper

3. Broad Process Setup Powder delivery system Fiber optic delivery
Laser head
Integrator lens
Custom power nozzle
Powder delivery line

4. Samples
Stainless to Steel
Inconel
(2 pass)
Stellite to Steel

5. Dilution Dilution typically less than 5% ~2.6% Dilution 6 mm L2 L1 A1

6. 10-kW Fiber Laser 316L on 4130 9- × 12-mm rectangular spot 8 kW
~1 mm build-up (single pass)

7. Submerged Arc Strip Cladding SASC
Typically 750 A, up to 40 lb/hr Typical dilution of 10-20%

8. Electroslag Strip Cladding
ESC - Typically 1400 A, up to 60 lb/hr, dilution 5-15%

9. Additive Manufacturing (AM) – An Extension of Cladding
From single beads stacked upon each other (bottom)
To large features at high deposition rates (top)
Mitigated by balance of net-shape, metallurgical requirements, mechanical properties (tensile, fatigue, etc.)

10. AM – Progressive Layers
Additive manufacturing - build in layers, stress relieve/PWHT, machine, as/if necessary

11. Deposition Rate vs Resolution
Courtesy Boeing
Decreased Resolution
Increased Deposition Rate

12. Summary
Surface engineering is a broad field ranging from ion implantation to explosive cladding in terms of the mass of material deposited in unit time.
Practical methods for powder and strip cladding areas large and small, across a range of industries, include fusion-based processes such as GTA, PTA, GMA, laser, SASC, and ESSC depending on the area to be clad, deposit thickness, and chemistry required. Others include thermal spray, e.g., HVOF.
Many processes require two layers to achieve the desired surface chemistry and corrosion resistance; others require only one layer.

13. Questions? Ian D. Harris Technology Leader, Arc Welding
Phone: