Laser cladding stainless steel filetype pdf

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Song, J. Echigoya, B. Zhu, C. Xie, W. Huang, and K. Ribanudo Nd J. Mazumder and D. Singh, K. Nagarathnam, and J. Singh, M. Zmuda, and J. A34—A34, Przbylowicz and J. Zeng, Z. Tao, B. Zhu, E. Zhou, and K. Techel, A. Luft, and W. Ouyang, T. Lei, and Y. Hidouci, F. Simonin, and J.

Yang, N. Chen, W. Kooi, Y. Pei, and J. Zhang, J. He, and W. Liu M. Yang, M. Zhong, and W. Corbin and D. Corbin, X. Zhao-jie, H. Henein, and P. Mortensen and S. Wu and Y. Automotive, aerospace, navy, defense, and many other sectors are widely adapting laser technology for welding, cutting, and hardening. Among the applications of laser technology, laser cladding has received significant at- tention in recent years due to its diversified potential for material processing such as metallic coating, high-value components repair, prototyping, and even low-volume manufacturing.

Laser cladding utilizes a laser heat source to deposit a thin layer of a desired metal on a moving substrate. The deposited material can be transferred to the substrate by several methods: powder injection, pre-placed powder on the substrate, or by wire feeding.

In this process, the laser beam melts the powder particles and a thin layer of the moving substrate to deposit a layer of the powder particles on the substrate. A great variety of materials can be deposited on a substrate using laser cladding by powder injection to form a layer with thicknesses ranging from 0. Integration of the laser cladding technology with a three-dimensional CAD solid model, which is sliced into many layers, provides the ability to fabricate complex components without intermediate steps.

The development of the laser cladding technology depends on enhancement of the technologies involved. Understanding the interconnections between the involved technologies and the process quality is a major step for the de- velopment of laser cladding. In the rapid prototyping or layered manufacturing applications, numerous names have been used.

In the powder injection laser cladding process, which is the focus of this book, a wide variety of names have been used as outlined below. The University of Missouri at Rolla also uses the same name for the process [46, 47]. This name can be confused with another laser-based technology, laser bending, which is also called laser rapid forming. Despite the variety of names, in practice all of the terms describe technol- ogy that share several common features: deposition of thin layers of powder particles melted by a laser heat source on a substrate.

The laser cladding technique can produce a much better coating, with minimal dilution, minimal distortion, and better surface quality. There are also a number of advantages to use this technique as a rapid prototyping technique.

Rapid prototyping can be used to produce a mechan- ical component in a layer-by-layer fashion, which enables the fabrication of part with features that may be unique to laser cladding prototyping, such as a homogeneous structure, enhanced mechanical properties, and one-step production of complex geometries. Parts fabricated using the technique are near net shape, but will generally require final machining.

They also have good grain structure, and have properties similar to, or even better than the intrinsic materials. This results in a number of benefits as follows: 4.

Reduction of production time: The length of time required to build a prototype is a problem for new product development. In many cases, both prototype and production tooling are needed; therefore, the length of time to produce a prototype and the necessary tooling can be several months.

The laser cladding process can reduce this time by fabricating tools and main prototypes directly from the CAD solid model [44]. In addition, this thermal zone can be monitored and optimized during the process, which can significantly improve the quality of the tools produced. Parts repair: Current tool repair technology relies on destructive, high-temperature welding processes. Laser cladding can be applied as a safe technology to repair tooling, especially on critical contacting surfaces.

Laser cladding increases tool life and in many cases can save a high-value tool that would otherwise need to be replaced [20, 36].

Production of a functionally graded part: In conventional metallic fabrication, it is di! Production of smart structure: In conventional metallic fabrication methods, embedding objects into the tools is impossible due to the na- ture of manufacturing. Encapsulating these objects reduces the potential for damage or failure from temperature and envi- ronmental conditions [39]. While laser cladding clearly of- fers a number of advantages over conventional fabrication technologies, the process can also have some drawbacks.

Due to disturbances in the process, the clad quality may vary significantly. Variations of the quality may even be observed between processing cycles performed using the same operating conditions. This poor reproducibility arises from the high sensitivity of laser cladding to small changes in the operating parameters such as laser power, beam velocity and powder feed rate, as well as to process disturbances such as variations in absorptivity. Finding an optimal set of parameters experimen- tally and using them in an open-loop laser cladding process may not result in a good quality clad due to random or periodic disturbances in the system.

High investment cost, low e! However, with continued technological developments in high-power diode lasers HPDL , fiber lasers, and sophisti- cated knowledge-based controllers, the laser cladding process shows a great industrial potential for use in metallic coating and prototyping applications. Immediately after this invention, scientists claimed that the laser was the answer to a multitude of scientific problems that might not have been even known during those years.

These problems had arisen in many areas resulting in lasers being adapted to many technologies to dissolve the problems with their unique features. The development of high-power gas lasers e. A pre-placed laser cladding method was used to investigate the feasibility of the process in applying dense ceramic cladding to metallic workpieces. At about the same time, several research groups around the world began projects to develop apparatus and systems for development and improvement of the process.

Among these groups, the project conducted by William M. He along with Vijitha Weerasinghe introduced laser cladding by powder injection to acad- emia and conducted a number of projects to evaluate the developed process [43, 44, 45, 46]. These papers disclosed the devices for enhancement of the technology, such as develop- ment of powder feeders, cooling systems, hemispherical reflecting device for re-absorbing the reflected light, etc.

Laser cladding was identified as a process with a significant edge over the conventional processes for wear and corrosion resistant coating. The first reported use of the laser cladding by industry was the hard-facing of Nimonic turbine blade interlock shrouds for the RB- jet engine at Rolls Royce in In , at Pratt and Whitney, the nickel-base alloy turbines of JT8 and JT9 engines were hard-faced using pre- placed laser cladding [59].

From a commercialization point of view, several companies, such as Avco Everett Metalworking Lasers Inc. In the automotive industry, laser cladding technology was transferred to the market for the engine valve seat coating by some European and Asian automotive companies, such as Fiat [58], Toyota [60], and Mercedes Benz.

Laser cladding was successfully utilized for re- building and coating of the H-dimension airfoil section thickness of worn tur- bine vanes, the tip of the turbine blades, and turbine bolts [58, 64, 36, 62, 63]. This process used ul- traviolet lasers to selectively cure photo polymer materials. In , the first commercial stereolithography machine was sold and a new industry in rapid prototyping was established. Stereolithography gave product developers the ability to quickly and accurately visualize, iterate, optimize, and fabricate new designs directly from a three-dimensional CAD solid model.

Although most commercial systems used polymers and photopolymers, the industry was looking for features to rapidly fabricate the metallic prototypes that could be directly used in real machines. Global competition was also forcing product manufacturers to look for new ways to reduce new product design time and manufacturing costs. The group examined building parts in one and two dimensions, taking into considera- tion both the time and cost involved in the process compared with traditional methods.

Due to the success of their project, the research group moved to the University of Michigan to conduct their research with more emphasis on automotive manufacturing. POM Inc. Many other research and development groups initiated projects to develop methods for prototyping metallic parts based on laser cladding by powder in- jection. Among them, Sandia National Laboratories, which is a multi-program laboratory operated by the Lockheed Martin Corporation, was funded by the Departments of Energy of the US government to conduct research for devel- opment of laser near shape fabrication methods.

The University of Liverpool research group, led by Steen, also began projects for laser direct manufactur- ing, which contributed extensively to this field [65, 66]. Their achievements had a great impact in this field due to the unique surface quality of the parts produced using their technique. In the last few years, a research group at the University of Waterloo con- ducted research for the development of an intelligent laser cladding apparatus.

These knowledge-based controllers will be eventually used in an autonomous laser cladding machine, which can not only deposit a wide range of alloys, but can also make the complex shapes without the need for the presence of specialists [34, 67, 68]. The flexibility of laser cladding is beginning to be recognized by many indus- tries and research groups.

The potential of this technology is great as research groups continue to contribute to its growth through research programs and training of students in laser cladding techniques technology. This changes the surface properties of the substrate to those of the deposited material.

The substrate becomes a composite material exhibiting properties generally not achievable through the use of the substrate material alone. The coating provides a durable, corrosion-resistant layer, and the core material provides the load bearing capability. There are many coating deposition techniques available.

However, selecting the best depends on many parameters such as size, metallurgy of the sub- strate, adaptability of the coating material to the technique intended, level of adhesion required, and availability and cost of the equipment.

However, with improvement of laser e! Another indication of the potential of laser cladding for coating of a variety of materials is the increase in the number of published papers and reports concerning the technology in the recent years. The majority of published papers related to the metallic coating by laser cladding address the use of several major materials in aerospace, medical, and automotive industries. Recently, the biocermics coating on titanium alloys was also performed by laser cladding; the coated parts are then used in orthopedic implants with a calcium phosphate layer in order to promote the growth of the bone when the implant is inserted in the body [83].

Laser cladding along with other laser surface treatment methods has also been examined for the production of glassy metallic layers, which provide superior resistance against wear and corrosion [84].

The most leading metallic coatings market for laser cladding is the coating of commercial aircraft gas turbines. In response to demands for the development of a higher e! The shroud interlock between turbine blades has been also hardfaced with Triballoy to reduce the wear due to sliding between blades during the warm up and cold down the engine.

Laser cladding has been recently used in this sector to deposit the mentioned materials on the spacecraft components. With recent technological improvements in the new generation of lasers, it is expected that laser cladding technology will take on an increasingly important role in this market.

In addition, laser cladding also has several other coating applications for industrial parts to produce surfaces, that are resistant to abrasive, erosive and adhesive wear; wet corrosion; and high temperature oxidation and corrosion.

Laser cladding can be used to rescue high-value components which are over- machined due to the errors in design or machining process. Conventional methods use welding to retrieve these damaged components; however, these methods are usually destructive due to the highly distributed temperature over the area of repair.

This thermal destruction causes a low mechanical quality, crack, porosity and very short life of the component. Laser cladding can provide a permanent structural repair and refurbishment on many alloys e.

An example of the repair by laser cladding of a shell made from high strength aluminum alloys i. This shell is used in undersea weapon components, which sustain wear and damage as a result of handling, operation and the corrosive nature of the saltwater environment.

Laser cladding has been applied to repair of such components. The results are promising such that the repairs are permanent. They stop corrosion and increase structural integrity [86].

One of the other areas, in which laser cladding plays an important role is turbine blades repair and refurbishment. Turbine blades are under very high thermal and mechanical stresses i. Therefore, in terms of maintenance requirements, manufacturing di! The low heat input property of laser cladding is the most unique char- acteristic of this technology that makes it highly attractive for jet engine components repair applications, in which metal depositions are required to be applied to superalloys.

These superalloys are highly susceptible to strength loss and physical distortion when exposed to excessive temperature variations. Conventional repair techniques, such as tungsten inert gas, metal inert gas, plasma and electron beam welding, usually cause a large amount of heat dur- ing weld metal deposition which results in large temperature increases in the body of the component.

The temperature increases above certain limits cause the base alloy to be weakened. This weakening along with component distor- tion can cause irreversible damage to the part. In contrast to conventional weld repair, the laser cladding process transfers heat only to localized areas, typically using a 0. An even greater repair market potential exists for the application of laser cladding in turbine engines.

More Filters. This article represents in complex form the results of surface layer creation by using laser beam. It contains results of research for surface layers creation by laser beam. It describes methods and … Expand. Development of an observation and control system for industrial laser cladding. It is not only applied for coating new products but also for repair and refurbishment as well as in rapid … Expand. View 3 excerpts, cites background.

Laser cladding process to enhanced surface properties of hot press forming die: A review. Materials Science, Physics. Laser cladding is one of the advance processes in laser surface treatments. The process involved a laser beam to combines another material that has different metallurgical properties on a substrate, … Expand. View 1 excerpt, cites background.

Laser cladding has been widely used in direct laser fabrication and laser refabrication for metal parts. It is a high precision and complicated process due to multiple process parameters involved. Fibre laser micro-cladding of Co-based alloys on stainless steel. A new … Expand. Laser Cladding vs. Laser Alloying — a Comparative Study.

While laser cladding is … Expand. View 2 excerpts, cites background. It describes methods and results of technological, material research as well as study of clad … Expand. State of the art of Laser Hardening and Cladding. In this paper an overview is given about laser surface modification processes, which are developed especially with the aim of hardness improvement for an enhanced fatigue and wear behaviour.

The … Expand. Microstructural characterization of Co-based coating deposited by low power pulse laser cladding. Journal of Materials Science. A detailed microstructural study of Stellite 6 coating deposited on a low carbon ferritic steel substrate using preplaced powder method and low power Nd:YAG pulse laser is performed.

The grain … Expand. View 1 excerpt, cites methods. Process optimization for directed energy deposition of SSL components. Directed energy deposition DED , also known as laser cladding, is a metal additive manufacturing process in which a high-power laser combined with a coaxial powder delivery system is used to … Expand. Laser cladding: the relevant parameters for process control.

Materials Science, Engineering. Other Conferences. We investigate the propagation of a high power CO2 laser beam through a powder stream in the condition of laser surface cladding.

During this process, a powder material and a gas are blown coaxially … Expand. Cross-section modeling of pulsed Nd:YAG laser cladding. We present in this work the parameters study in case of laser cladding stellite 6 onto stainless steel with a pulsed Nd:YAG laser and sprayed powder.

We characterize the clads by geometrical … Expand.