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5221 |
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Thursday, June 08, 2017, Hall 26 2:00 PM Laser Cladding & PTA |
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Advanced processes and system technology for high-performance laser cladding |
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Steffen Nowotny* / Fraunhofer Institute for Material and Beam Technology, Germany Holger Hillig/ Fraunhofer IWS Dresden, Germany Frank Kubisch/ Fraunhofer IWS Dresden, Germany Robin Willner/ Fraunhofer IWS Dresden, Germany Filofteia-Laura Toma/ Fraunhofer IWS Dresden, Germany Christoph Leyens/ Technical University Dresden, Germany |
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Laser cladding technology is widely used in industry to precisely apply tailored surface coatings as well as three-dimensional deposits for repair and additive layer-by-layer fabrication of metallic parts. However, the processing of larger components, like tools for oil and gas production, is economically challenging due to the conventionally low deposition rates. Consequently, industry is requesting more powerful technologies that maintain the quality advantages of the laser technology, but also make the process more productive and time effective. Against this background, modern highest-power diode lasers offer practical solutions for large-area laser cladding with significantly increased productivity. Using a fiber-coupled diode laser of 20 kW power and the accordingly develo¬ped laser cladding heads, real deposition rates of metal alloys, e.g. INCONEL625, amount to 15 kg/h. The maximum width of a single track is 45 mm at 20 kW when using a powder nozzle with rectangular profile of the powder jet. Besides the laser source, the processing head has a key function for productivity and efficiency of the whole cladding procedure. The paper presents a new generation of high-performance laser cladding heads with integrated process sensors, which guarantee a stable long-time operation at highest power levels. The deposition rates achieved with this technology equal or even exceed typical values of the common PTA technique. Anyhow, the coatings show the laser-typical quality in form of low dilution of 4 to 7%, high accuracy, and good surface quality of the as-deposited layers. Current applications are large-area coatings on power plant components, hydraulic cylinders for off-shore equipment, and large metal forming tools for automotive bodies. |