Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Additive Manufacturing: Budget-friendly retrofit of module for wire-based laser deposition welding

05.10.2018

When economic or safety considerations rule out the use of powder materials in additive manufacturing, the option of wire-feed laser deposition welding resents itself. The Fraunhofer Institute for Production Technology IPT in Aachen has developed a smart laser module for wire deposition welding, which can easily be integrated within existing process chains, handling systems or machine tools. The engineers from Aachen will be unveiling the LMD-W-20-L module for the first time to the visitors from industry at Formnext, the Fair for Additive Technologies in Frankfurt/Main, Hall 3, Booth E70, 13-16 November 2018.

3D powder bed printing is currently the most well-known additive manufacturing process for filigree and complex metallic parts. A laser fuses the powdered material with pinpoint accuracy in a closed unit. However, there are two other less well-known additive processes which are particularly suitable for repairing or modifying larger-scale parts: powder-based and wire-fed laser deposition welding.


Processing head "LMD-W-20-L" for wire-based laser deposition welding.

Graphic: Fraunhofer IPT

Deposition welding performed using local infeed of firm, wire material is significantly more material-efficient and environmentally-friendly than powder-based laser deposition welding in which the material flows in the form of tiny particles at high pressure out of nozzle and onto the component to be melted there by the laser.

Due to the easy to handle additive material, wire-feed deposition welding, also known as Laser Metal Deposition – Wire (or LMD-W) is highly suitable for integration in existing production lines. However, the process is considerably more complex to control and therefore more fault-prone than powder-based deposition welding.

Consequently, it has previously been used mainly for rough pre-machining operations. The “LMD-W-20-L” laser machining head, developed by the Fraunhofer IPT in Aachen, is a retrofit solution, whose sturdy construction and smart sensor system equip it for combination even with industrial robot systems in the medium term.

The modular LMD head integrating conventional process chains

The cost-effective welding head works with commercially available laser optics and and does not require complex custom-made beam guidance systems. In future it will be possible to record typical faults as they arise in the course of an on-going process, permitting the causes to be analyzed during the operation and to be offset by the control system.

Lateral wire infeed at a steep angle of 20 degrees to the optical axis ensures stable processes with high fusing efficiency. The range of wire materials available already includes various types of steel, nickel and titanium-based alloys along with numerous special purpose materials. The Fraunhofer IPT is currently exploring the suitability of other alloys as part of a number of research projects.

LMD-W – Additive process with 100 percent material efficiency

The stand-out characteristic of wire-based laser deposition welding is the quasi 100 percent material efficiency since the material fed in is melted completely and applied layer-by-layer to the surface of the part.

Given the CAM support required and multi-axis process control, additional functional elements can be added to existing parts to produce a hybrid construction and permitting repairs or modifications to be undertaken. A wide range of wire based additional materials can be processed not only very cost-efficiently but also in near-net-shape ensuring that the parts turned out are of premium quality.

This press release and a printable photo are also available on the internet: http://s.fhg.de/LMD-W-20-L

Wissenschaftliche Ansprechpartner:

Stefan Gräfe M.Eng.

Fraunhofer Institute for Production Technology IPT
Steinbachstraße 17
52074 Aachen, Germany
www.ipt.fraunhofer.de/en
stefan.graefe@ipt.fraunhofer.de

Weitere Informationen:

http://s.fhg.de/LMD-W-20-L

Susanne Krause | Fraunhofer-Institut für Produktionstechnologie IPT

More articles from Machine Engineering:

nachricht More functionalities: Microstructuring large surfaces with a UV-laser system
05.07.2018 | Fraunhofer-Institut für Lasertechnik ILT

nachricht A factory to go
04.07.2018 | Fraunhofer Institute for Manufacturing Engineering and Automation IPA

All articles from Machine Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Flying High with VCSEL Heating

Additive manufacturing processes are booming, with the rapid growth of the formnext trade fair a clear indication of this. At formnext 2018, the Fraunhofer Institute for Laser Technology ILT will be showing a new process in which the component in the powder bed is heated with laser diodes. As a result, distortion can be reduced, taller parts generated and new materials used.

In just three years, formnext has established itself as the industry meeting place to get the latest on additive manufacturing (AM) processes. With 470...

Im Focus: Breakthrough in quantum physics: Reaction of quantum fluid to photoexcitation of dissolved particles

Researchers from Graz University of Technology have described for the first time the dynamics which takes place within a trillionth of a second after photoexcitation of a single atom inside a superfluid helium nanodroplet.

In his research, Markus Koch, Associate Professor at the Institute of Experimental Physics of Graz University of Technology (TU Graz), concentrates on...

Im Focus: Chemists of TU Dresden develop highly porous material, more precious than diamonds

World Record of Cavities

Porosity is the key to high-performance materials for energy storage systems, environmental technologies or catalysts: The more porous a solid state material...

Im Focus: New function of “kidney-gene”: WT1 plays a role in the central nervous system and controls movement

The WT1 gene fulfills a central role in the development of a healthy, proper functioning kidney. Mutations in WT1 lead to impairments in kidney development and cause Wilms tumors, a pediatric kidney cancer. Researchers of the Leibniz Institute on Aging – Fritz Lipmann Institute (FLI) in Jena have now discovered a further important function of WT1. It is also active outside the kidneys in the central nervous system and is involved in controlling movement. If the gene is missing in the spinal cord, locomotor aberrancies occur. The results have now been published in Life Science Alliance.

Transcription factor WT1 (Wilms tumor 1) has been known for nearly 30 years and it is significantly involved in the development of a healthy and properly...

Im Focus: Master of the tree – novel form of dendritic inhibition discovered

A unique feature that sets neurons apart from all other cells are their beautiful, highly elaborate dendritic trees. These structures have evolved to receive the vast majority of information entering a neuron, which is integrated and processed by virtue of the dendrites’ geometry and active properties. Higher brain functions such as memory and attention all critically rely on dendritic computations, which are in turn controlled by inhibitory synaptic input. A team of scientists, led by Johannes J. Letzkus (MPI for Brain Research), now has identified a novel form of inhibition that dominantly controls dendritic function and strongly depends on previous experiences.

Our brain is a remarkably complex system. It is not only comprised of billions of neurons, but each individual neuron by itself even has exceptional processing...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

VideoLinks
Industry & Economy
Event News

5th International Conference on Cellular Materials (CellMAT), Scientific Programme online

02.10.2018 | Event News

Major Project: The New Silk Road

01.10.2018 | Event News

"Boston calling": TU Berlin and the Weizenbaum Institute organize a conference in USA

21.09.2018 | Event News

 
Latest News

Raman spectroscopy allows fast analysis of vaccines

04.10.2018 | Life Sciences

Scientists discover new nursery for superpowered photons

04.10.2018 | Physics and Astronomy

Molecular multitools

04.10.2018 | Materials Sciences

VideoLinks
Science & Research
Overview of more VideoLinks >>>