almir heralić, anna-karin christiansson, mattias ottosson, university west
DESCRIPTION
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?. - PowerPoint PPT PresentationTRANSCRIPT
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Almir Heralić, 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
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Laser Metal Deposition
Almir Heralić, University West
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
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Laser Metal Deposition
Almir Heralić, University West
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Laser Metal Deposition
Almir Heralić, University West
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Laser Metal Deposition
Almir Heralić, University West
Metal deposition example
Deposition movie
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Laser Metal Deposition
Almir Heralić, University West
Close-up view of the melt pool
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Laser Metal Deposition
Almir Heralić, University West
Some applications
Prototyping
New manufacturing – Fabrication– Shape modification
High-value component repair or modification
…
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Laser Metal Deposition
Almir Heralić, University West
Fabrication
Welding, forging, machining, casting, metal deposition, sheet metal forming
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Laser Metal Deposition
Almir Heralić, University West
Fabrication – example Ti-6Al-4V
sheet metal + welding
LMD (weld prep)LMD
machining + welding
casting
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Laser Metal Deposition
Almir Heralić, University West
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
Process advantages - LMD
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Laser Metal Deposition
Almir Heralić, University West
Demanding from a sensor and
measurement point of view
The process is not fully understood
The use of wire imposes certain limitations
...
Identified difficulties
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Laser Metal Deposition
Almir Heralić, University West
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
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Laser Metal Deposition
Almir Heralić, University West
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
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Laser Metal Deposition
Almir Heralić, University West
Laser power/wire speed vs. weld quality
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Laser Metal Deposition
Almir Heralić, University West
Results – manual control
Common errors without feedback
Manual control with feedback
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Laser Metal Deposition
Almir Heralić, University West
Automation of LMD
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Laser Metal Deposition
Almir Heralić, University West
Welding tool - sensor configuration
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Laser Metal Deposition
Almir Heralić, University West
Feedforward height control
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Laser Metal Deposition
Almir Heralić, University West
PI-control of bead width
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Laser Metal Deposition
Almir Heralić, University West
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
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Laser Metal Deposition
Almir Heralić, University West
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
Future work