LMDCAM2: Software Tool for Near-Net Repair, Cladding and Built-Up by Laser Metal Deposition

2015 ◽  
Author(s):  
John Flemmer ◽  
Norbert Pirch ◽  
Fabian Drinck
Keyword(s):  
Tool Path ◽  
Laser Scanner ◽  
Software Tool ◽  
Metal Deposition ◽  
Design Stage ◽  
Laser Metal Deposition ◽  
Tool Paths ◽  
Wide Range ◽  
Subtractive Manufacturing ◽  
Manufacturing Applications

Laser Metal Deposition (LMD) is growing in importance as a technique for the processing and manufacturing of parts in industry. LMD is used for a wide range of applications including the repair of worn parts, the built-up of 3D structures and the surface functionalization trough cladding. In many cases, the nominal CAD model from the design stage is no longer suitable for the representation of the part geometry due to distortion or defects especially in case of a worn part. This means for the generation of close contoured tool paths it is essential to create a digital model representing the surface of the actual part. This digitalization is often achieved by using a laser scanner whose raw output is represented by point cloud. Tool path planning software (CAM) available on the market generally demonstrate substantial deficits in generating paths on scanned surface data, because these programs are usually optimized on NURBS based surfaces and in most cases were originally designed for subtractive manufacturing applications. LMDCAM2 represents a new software tool especially designed for the LMD process. It is optimized for working with 3D scanned, triangulated data based models which could include noisy data and offers fundamental features for creating and manipulating tool paths adapted to the LMD process. Besides algorithms for calculating close contoured equidistant tracks, the software is also able obtain tracks for additive production through advanced slicing techniques of a 3D model.

scholarly journals Effect of Interlayer Cooling Time, Constraint and Tool Path Strategy on Deformation of Large Components Made by Laser Metal Deposition with Wire

2019 ◽  
Vol 9 (23) ◽  
pp. 5115 ◽  
Author(s):  
Yousub Lee ◽  
Yashwanth Bandari ◽  
Peeyush Nandwana ◽  
Brian. T. Gibson ◽  
Brad Richardson ◽  
...  
Keyword(s):  
Finite Element Method ◽  
Residual Stresses ◽  
Material Properties ◽  
Large Scale ◽  
Tool Path ◽  
Metal Deposition ◽  
Cooling Time ◽  
Laser Metal Deposition ◽  
Structural Components ◽  
Part Distortion

Laser metal deposition with wire (LMD-w) is a developing additive manufacturing (AM) technology that has a high deposition material rate and efficiency and is suitable for fabrication of large aerospace components. However, control of material properties, geometry, and residual stresses is needed before LMD-w technology can be widely adopted for the construction of critical structural components. In this study, we investigated the effect of interlayer cooling time, clamp constraints, and tool path strategy on part distortion and residual stresses in large-scale laser additive manufactured Ti-6Al-4V components using finite element method (FEM). The simulations were validated with the temperature and the distortion measurements obtained from a real LMD-w process. We found that a shorter interlayer cooling time, full clamping constraints on the build plates, and a bidirectional tool path with 180° rotation minimized part distortion and residual stresses and resulted in symmetric stress distribution.

Characterization of Colmonoy 227-F Samples Obtained by Direct Laser Metal Deposition

2009 ◽  
Vol 83-86 ◽  
pp. 842-849 ◽  
Author(s):  
Andrea Angelastro ◽  
Sabina L. Campanelli ◽  
Antonio D. Ludovico
Keyword(s):  
Computer Aided Design ◽  
Complex Geometry ◽  
Scanning Speed ◽  
Glass Container ◽  
Metal Deposition ◽  
Laser Metal Deposition ◽  
Metal Powders ◽  
Wide Range ◽  
Direct Laser ◽  
Direct Laser Metal Deposition

Direct Laser Metal Deposition (DLMD) is an emerging technique in the group of Material Accretion Manufacturing (MAM) processes because of the possibility to fabricate and to repair a wide range of metal components with a complex geometry, starting from metal powders. DLMD is a technology which combines computer aided design, laser cladding and rapid prototyping. Fully dense metallic parts can be directly obtained through melting coaxially fed powders with a laser. The success of this technology in the die and tool industry depends on the parts quality to be achieved. An accurate control of the parameters such as laser power, spot diameter, scanning speed and powder mass flow rate is fundamental to obtain the required geometric dimensions and material properties. In this work, the performance of the DLMD process was examined in terms of hardness, porosity, microstructure, and composition. A fitting equipment was built and used for the experiments together with a CO2 laser machine with a maximum power of 3 kW. The material used for experimental tests was Colmonoy 227-F, a Nickel alloy specially designed for glass container mould protection and restoration.

scholarly journals Pulsed Laser Influence on Temperature Distribution during Dual Beam Laser Metal Deposition

Metals ◽  
2020 ◽  
Vol 10 (6) ◽  
pp. 766
Author(s):  
Marius Gipperich ◽  
Jan Riepe ◽  
Kristian Arntz ◽  
Thomas Bergs
Keyword(s):  
Temperature Distribution ◽  
Continuous Wave ◽  
Metal Deposition ◽  
Process Conditions ◽  
Laser Metal Deposition ◽  
Effective Absorption Coefficient ◽  
Positive Effects ◽  
Real Process ◽  
Dual Beam ◽  
Wide Range

Wire-based Laser Metal Deposition (LMD-w) is a suitable manufacturing technology for a wide range of applications such as repairing, coating, or additive manufacturing. Employing a pulsed wave (pw) laser additionally to the continuous wave (cw) process laser has several positive effects on the LMD process stability. The pw-plasma has an influence on the cw-absorption and thus the temperature distribution in the workpiece. In this article, several experiments are described aiming to characterize the heat input during dual beam LMD. In the first setup, small aluminum and steel disks are heated up either by only cw or by combined cw and pw radiation. The absorbed energy is then determined by dropping the samples into water at ambient temperature and measuring the water’s temperature rise. In a second experiment, the temperature distribution in the deposition zone under real process conditions is examined by two-color pyrometer measurements. According to the results, the pw plasma leads to an increase of the effective absorption coefficient by more than 20%. The aim of this work is to achieve a deeper understanding of the physical phenomena acting during dual beam LMD and to deploy them selectively for a better and more flexible process control.

Evaluation of geometrical benchmark artifacts containing multiple overhang lengths fabricated using material extrusion technique

2020 ◽  
Vol 14 (3) ◽  
pp. 7296-7308
Author(s):  
Siti Nur Humaira Mazlan ◽  
Aini Zuhra Abdul Kadir ◽  
N. H. A. Ngadiman ◽  
M.R. Alkahari
Keyword(s):  
3D Model ◽  
Laser Scanner ◽  
Dimensional Accuracy ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Layer Technique ◽  
Subtractive Manufacturing ◽  
Manufacturing Features ◽  
Layer Problem

Fused deposition modelling (FDM) is a process of joining materials based on material entrusion technique to produce objects from 3D model using layer-by-layer technique as opposed to subtractive manufacturing. However, many challenges arise in the FDM-printed part such as warping, first layer problem and elephant food that was led to an error in dimensional accuracy of the printed parts especially for the overhanging parts. Hence, in order to investigate the manufacturability of the FDM printed part, various geometrical and manufacturing features were developed using the benchmarking artifacts. Therefore, in this study, new benchmarking artifacts containing multiple overhang lengths were proposed. After the benchmarking artifacts were developed, each of the features were inspected using 3D laser scanner to measure the dimensional accuracy and tolerances. Based on 3D scanned parts, 80% of the fabricated parts were fabricated within ±0.5 mm of dimensional accuracy as compared with the CAD data. In addition, the multiple overhang lengths were also successfully fabricated with a very significant of filament sagging observed.

Integration of pure copper to optimize heat dissipation in injection mould inserts using laser metal deposition

2021 ◽  
Vol 33 (1) ◽  
pp. 012029
Author(s):  
Stefan Polenz ◽  
Christian Kolbe ◽  
Florian Bittner ◽  
Elena López ◽  
Frank Brückner ◽  
...  
Keyword(s):  
Heat Dissipation ◽  
Pure Copper ◽  
Metal Deposition ◽  
Laser Metal Deposition ◽  
Injection Mould

POWDER BEAM ANALYSIS OF LASER METAL DEPOSITION COAXIAL NOZZLE VIA IMAGE PROCESSING

2019 ◽  
Author(s):  
Doglas Negri ◽  
Gustavo Reis de Ascencao ◽  
Saulo Melotti ◽  
Jhonattan Gutjahr
Keyword(s):  
Image Processing ◽  
Metal Deposition ◽  
Laser Metal Deposition ◽  
Coaxial Nozzle ◽  
Beam Analysis

TRIBOLOGICAL EVALUATION OF NI-CR-B-SI COATINGS DEPOSITED BY LASER METAL DEPOSITION AND TREATED BY LASER REMELTING

2019 ◽  
Author(s):  
Jurandir Sousa ◽  
Adriano de Souza Pinto Pereira ◽  
Rafael Gomes Nunes Silva ◽  
Calil Amaral ◽  
Milton Pereira
Keyword(s):  
Metal Deposition ◽  
Laser Metal Deposition ◽  
Laser Remelting
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