Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

One light arc, two wires and a laser: HoDopp – high power deposition welding

11.03.2015

Instead of completely exchanging expensive components after wear and tear, these can be repaired using deposition welding. Up to now, a gas metal arc welding (GMAW) process has usually been used for deposition welding, with an average feed rate of five kilos per hour.

Since the dilution level is around 30 percent, several layers must be deposited, one on the other, until the protective covering is pure enough. Scientists at the Laser Zentrum Hannover e.V. (LZH) have now, as part of the project HoDopp, developed a laser-supported, light arc process, which achieves this in a single layer.


Setup of the laser supported welding process.

Photo: LZH


The laser supported process is characterized by a smaller heat affected zone, a lower welding depth, and thus a lower dilution rate (layer height around 4 mm) (Photo: LZH)

Photo: LZH

In the conventional process, the light arc burns between the wire electrode and the workpiece, and fuses both. For large area and multi-layer coatings, the process can take up to 24 hours per square meter. On the other hand, in the process used by the LZH, a light arc burns between two wires and melts them simultaneously.

The deposition rate can thus be increased to around 7.5 kg per hour. The laser beam, which is used in addition to this, assures layer adherence, and improves the form of the seam.

Low thermal stress on the components

Due to the support by the laser beam, the layer is deposited with a low penetration depth, and the dilution rate is thus under five percent. A further advantage of the process is low heat input. Component deformation is notably lower than with deposition welding using conventional GMAW, and the deposition rate can be increased by around 50%.

Since one layer replaces two or three conventionally deposited layers, time and material can be saved for inhomogeneous materials, by half to two-thirds. Thus, productivity and simultaneously the quality of the welding process can be drastically increased.

The project HoDopp: “High-power laser cladding using the twin-wire technique without light-arc transmission and with laser-assisted weld-penetration control” was financed by the Federal Ministry of Education and Research (BMBF). The project was completed at the end of 2014.

The LZH is presenting the process setup and finished components at the Hannover Messe 2015, at the joint stand of the State of Lower Saxony, hall 2, stand A08.

Weitere Informationen:

http://www.lzh.de/en/publications/pressreleases/2015/hodopp-high-power-depositio... - website of the press release with video

Lena Bennefeld | Laser Zentrum Hannover e.V.

More articles from Process Engineering:

nachricht New technology for ultra-smooth polymer films
28.06.2018 | Fraunhofer-Institut für Organische Elektronik, Elektronenstrahl- und Plasmatechnik FEP

nachricht Diamond watch components
18.06.2018 | Schweizerischer Nationalfonds SNF

All articles from Process Engineering >>>

The most recent press releases about innovation >>>

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

Im Focus: Future electronic components to be printed like newspapers

A new manufacturing technique uses a process similar to newspaper printing to form smoother and more flexible metals for making ultrafast electronic devices.

The low-cost process, developed by Purdue University researchers, combines tools already used in industry for manufacturing metals on a large scale, but uses...

Im Focus: First evidence on the source of extragalactic particles

For the first time ever, scientists have determined the cosmic origin of highest-energy neutrinos. A research group led by IceCube scientist Elisa Resconi, spokesperson of the Collaborative Research Center SFB1258 at the Technical University of Munich (TUM), provides an important piece of evidence that the particles detected by the IceCube neutrino telescope at the South Pole originate from a galaxy four billion light-years away from Earth.

To rule out other origins with certainty, the team led by neutrino physicist Elisa Resconi from the Technical University of Munich and multi-wavelength...

Im Focus: Magnetic vortices: Two independent magnetic skyrmion phases discovered in a single material

For the first time a team of researchers have discovered two different phases of magnetic skyrmions in a single material. Physicists of the Technical Universities of Munich and Dresden and the University of Cologne can now better study and understand the properties of these magnetic structures, which are important for both basic research and applications.

Whirlpools are an everyday experience in a bath tub: When the water is drained a circular vortex is formed. Typically, such whirls are rather stable. Similar...

Im Focus: Breaking the bond: To take part or not?

Physicists working with Roland Wester at the University of Innsbruck have investigated if and how chemical reactions can be influenced by targeted vibrational excitation of the reactants. They were able to demonstrate that excitation with a laser beam does not affect the efficiency of a chemical exchange reaction and that the excited molecular group acts only as a spectator in the reaction.

A frequently used reaction in organic chemistry is nucleophilic substitution. It plays, for example, an important role in in the synthesis of new chemical...

Im Focus: New 2D Spectroscopy Methods

Optical spectroscopy allows investigating the energy structure and dynamic properties of complex quantum systems. Researchers from the University of Würzburg present two new approaches of coherent two-dimensional spectroscopy.

"Put an excitation into the system and observe how it evolves." According to physicist Professor Tobias Brixner, this is the credo of optical spectroscopy....

All Focus news of the innovation-report >>>

Anzeige

Anzeige

VideoLinks
Industry & Economy
Event News

Leading experts in Diabetes, Metabolism and Biomedical Engineering discuss Precision Medicine

13.07.2018 | Event News

Conference on Laser Polishing – LaP: Fine Tuning for Surfaces

12.07.2018 | Event News

11th European Wood-based Panel Symposium 2018: Meeting point for the wood-based materials industry

03.07.2018 | Event News

 
Latest News

A smart safe rechargeable zinc ion battery based on sol-gel transition electrolytes

20.07.2018 | Power and Electrical Engineering

Reversing cause and effect is no trouble for quantum computers

20.07.2018 | Information Technology

Princeton-UPenn research team finds physics treasure hidden in a wallpaper pattern

20.07.2018 | Materials Sciences

VideoLinks
Science & Research
Overview of more VideoLinks >>>