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Almir Heralić, Anna-Karin Christiansson, Mattias Ottosson, University West

Laser Metal Deposition: Supporting technology for manufacture of complex structures in the aero industry. Almir Heralić, Anna-Karin Christiansson, Mattias Ottosson, University West Torbjörn Norlander, Peter Jonsson, Börje Nordin, Volvo Aero. FLUD - VINNOVA. What is Metal Deposition?.

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Almir Heralić, Anna-Karin Christiansson, Mattias Ottosson, University West

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  1. Laser Metal Deposition: Supporting technology for manufacture of complex structures in the aero industry Almir Heralić, Anna-Karin Christiansson, Mattias Ottosson, University West Torbjörn Norlander, Peter Jonsson, Börje Nordin, Volvo Aero FLUD - VINNOVA

  2. What is Metal Deposition? • Metal deposition is an additiveprocess that joins metal beads • side-by-side • layer-by-layer • according to predefined paths. • Beads are formed by melting metal wire (or powder) using a heat source, e.g. a laser or other welding equipment

  3. Metal deposition example Deposition movie

  4. Close-up view of the melt pool

  5. Some applications • Prototyping • New manufacturing • Fabrication • Shape modification • High-value component repair or modification • …

  6. Fabrication Welding, forging, machining, casting, metal deposition, sheet metal forming

  7. Fabrication – example Ti-6Al-4V machining + welding sheet metal + welding LMD LMD (weld prep) casting

  8. Process advantages - LMD • Standard welding cell rather than specially made high-cost equipment • Laser heat source implies low heat input • Metal wire instead of powder • A 6-axis robot offers flexibility • Reduction in waste material and energy • Potential for cost efficiency and shorter lead times

  9. Identified difficulties • Demanding from a sensor and measurement point of view • The process is not fully understood • The use of wire imposes certain limitations • ...

  10. Process related difficulties • Several process parameters need careful tuning to obtain a stable process. • For example: • Laser power/wire speed ratio • Wire tip position relative the weld pool • Estimated bead height

  11. Process related difficulties Incorrect process parameters usually lead to: • formation of droplets gives irregular deposition • insufficient melting of the wire can lead to lack of fusion

  12. Laser power/wire speed vs. weld quality

  13. Results – manual control Common errors without feedback Manual control with feedback

  14. Automation of LMD

  15. Welding tool - sensor configuration

  16. Feedforward height control

  17. PI-control of bead width

  18. Results • Developed an LMD cell with a sensor- and measurement system • Stable process ensured, manual/automatic control • Good dimensional accuracy • Reduced risk for lack of fusion defects

  19. Future work University West / industrial partners: Increase the knowledge about the LMD process, e.g. temperature influence on the geometrical and mechanical properties of the deposited parts. Develop Off-Line Programming tools. Manufacturing industry: Work towards industrialization of the LMD process

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