laser engineered net shaping (lens)
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developedatSandiaNationalLaboratory NewMexico USAdevelopedatSandiaNationalLaboratory,NewMexico,USAandcommercialised byOptomec,USA
presented byPS h IITKhPSaha IITKharagpur
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Motivationbehinddevelopmentp Fullydense functionalmetallic components. Pickand placematerialcomposition totailorp plocalizedmaterialcharacteristics withinapart.
Repairandoverhaul technologiestoextendthelifeofcomponentsinagingaircraft ship vehicles andweaponcomponentsinagingaircraft,ship,vehicles,andweaponsystems. Convetional repairtechniquessuchasMIGorTIGweldinginduce
excessiveheatandalargeHEATAFFECTEDZONE(HAZ)excessiveheatandalargeHEATAFFECTEDZONE(HAZ)destroyingusefulnessofthepart.
Highcostofscrappingormaintainingcriticalparts,especially,whendrawingsdonotexist,whendrawingsdonotexist,
Partsdeemednonrepairableduringtheirrepairprocess Fabricate sparepartasandwhenrequiredfromitsoriginalCADdesign ratherthankeepingahugeinventoryoriginalCADdesign,ratherthankeepingahugeinventory.
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Schematic of the LENS processSchematicoftheLENSprocess
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LENSProcessstepsp Acomponentisfabricatedbycreatingamoltenpoolthroughfocusingalaserbeam ontoasubstrate.
Metalpowder particlesaresimultaneouslyinjectedintothepooltoaddmaterial.
Usingcomputercontrol thesubstrateismovedbeneath Usingcomputercontrol,thesubstrateismovedbeneaththelaserbeam intheXYplane,depositingathincrosssectionofpredeterminedCADgeneratedgeometry.Af d i i f l h d i i h d Afterdepositionofalayer,thedepositionhead(consistingofapowderdeliverynozzleandfocusinglensassembly)isincrementedinthepositiveZdirection,ll i i f h l f h allowinggenerationofthenextlayerofthepart.
Depositionoflayersisrepeateduntilthedesiredthreedimensionalcomponenthasbeenlayeradditivelyformed.dimensionalcomponenthasbeenlayeradditivelyformed.
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Powderdeliverynozzle
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ConstructionofthinwalledstructurewithfournozzleConstructionofthin walledstructurewithfournozzlepowderdeliverysystem
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NdYAGlaservs.CO2 laser Sinceitisundesirable
tovaporizemateial asitisdeposited opticalitisdeposited,opticalabsorptionofmaterialiscriticalforeffectiveutilizationoflaserenergy.
Withtheexceptionofcopper allofthecopper,alloftheelementalmetalsshowninthegraphhavesignificantlyg yabsorptionattheNdYAGlaserwavelengthascomparedtoCO2laserlaser.
Fiberlaserat1070nmhassimilarabsorptionasthatofNdYAGlaser11/11/2013 7PSaha
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CapabilitiesofLENSprocessp p Abilitytobuildfullydense shapes Closedloopcontrol ofprocessforaccuratepartfabrication
Abilit t t il dd iti t t f t i f d Abilitytotailoreddeposition parameterstofeaturesizeforspeed,accuracy,andpropertycontrol
Compositeandfunctionallygraded materialdeposition ThreeaxisandfouraxissystemsforcomplexpartfabricationThree axisandfour axissystemsforcomplexpartfabrication Withthistechnology,materialsthateithercannotbe cast andthermo
mechanicallyprocessed,orthatcannotbeconsolidated successfullybypowdermetallurgy,canbeformed.
d f l h l d l l ll Widevarietyofmaterials that,atminimum,include:stainlesssteelalloys(316,304L,309,174),maraging steel (M300),nickelbasedsuperalloys(Incodesignations625,600,718,690),toolsteel alloys(H13),titaniumalloy(6Al4V),andotherspecialtymaterials( 4 ), p y
Highcoolingrate(102 103 K/s)leadsto finermicrostructure Mechanicalproperties similarorbetter thantraditionalprocessing
methods
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VaryingCompositiony g p Multiplepowderdeliverynozzlesarecapableofvaryinglocalcompositionvaryinglocalcomposition.
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Different Build Styles with VaryingDifferentBuildStyleswithVaryingCompositionpDependingonthedesigncriterionofapart,materialcompositioninLENScanbevariedthroughcompositioninLENScanbevariedthrough compositematerialdeposition thepowdercompositionremainsconstantfordistinctbuildpregions,and
functionallygradedmaterial(FGM) depositionthepowdercompositioniscontinuouslychanging
FGMrequiresaheavierinteraction betweenthepowderfeedercontroller andtheLENSmotioncontrollercontroller.
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(a)AcompositeconsistsofdistinctregionsofAandB (b)CompositesmaybeconstructedbyfirstdrawingallofregionAandthen (c)drawingallofregionB,allowingpowderfeederstobereconfiguredbetweencompositions. (d)FGMsrequirethepowdertobecontinuallyvariedthroughoutthebuild (d)FGMsrequirethepowdertobecontinuallyvariedthroughoutthebuild. (e)eachdepositionvectorinanFGMbuildwillhaveauniquepowderfeederprofile.
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PowderFeederCharacterization
PowderFeederSetUp(Feeder,Screw,Feedlinelengthetc.)
Powderistransportedfromapowderhoppertothegasstream Ascrewfeeddevice usesanopenthreadedshafttometerpowderintoan
argoncarriergasstreamargoncarriergasstream Asinglecarriergaslineisdividedintotwodistinctflows,passedthrough
thefeedersandthenrecombinedintoasingleline. Mixingofthetwopowders occursnaturallyintherejoinedargonstreamg p y j g
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Forcomposites,thechiefcriterionforsuccessfuldepositionisthatthepowderfeedersprovidethedesireddepositionisthatthepowderfeedersprovidethedesiredpowdercompositionforagivenperiodoftime.Thesystemcaneffectivelypauselongenough forpowdery p g g pcompositionstobealteredandreachsteadystate.
ForFGMs,thereisasignificanttimelagbetweenaskingforagivencompositionandwhenthatcompositionisactuallyi j di h l lb i i l H injectedintothemoltenpoolbecomescritical.Hencethoroughcharacterizationofpowderfeederisneeded.
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OPTOMECs FOPTOMEC sLENS850SYSTEM
Features 1100Wcontinuous
NdYAGlaserd G ase Fiberopticbeam
delivery 18x18x42build 18 x18 x42 build
envelop 4th and5th axis:rotary
andtiltstagesandtiltstages Controlargon
atmospherewithoxygensensoroxygensensor
FilteringsystemforparticulatecontrolCCD i i CCDvision
Glovebox Power220V3phasePower220V3phase
100A11/11/2013 14PSaha
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S 8 0 ifi iLENS850systemspecifications
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Materials deposited using the LENSMaterialsdepositedusingtheLENSProcess
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Measured tensile values for LENS vMeasuredtensilevaluesforLENSv.forged/annealedspecimensg / p
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ApplicationsofLENSpp ToolingapplicationsforInjectionMoldToolingandDie
Casting whereLENS'canimprovecycletimesby50%andg p y y 5extendmoldlife. Conformalcoolingchannelsarepossible.
RepairandOverhaul applicationsduetosmallHeatAffectedZone(HAZ) allowingforhigheryieldandsuperiorpartrepairsZone(HAZ),allowingforhigheryieldandsuperiorpartrepairs.
Functional"PrototypingandSmallLotManufacturingmadepossibleduetoproducingfullydensemetalpartswith
di h i l i (hi h h&d ili ) outstandingmechanicalproperties(highstrength&ductility),notfoundwithRapidPrototypingsystems
MaterialResearch :improvementofpropertiesinexistingp p p galloysandcomposites;developmentofnewalloysandcomposites.LENS'abilitytoprovidemultiplematerialgradientdepositionoffersuniquematerialresearchoptionsdepositionoffersuniquematerialresearchoptions.
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Applicationspp
Building Up of Turbine Blade Finished TurbineBuilding Up of Turbine Blade by LENS
Finished Turbine Blade
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Applicationspp
H13 Tooling
Thin Walled Housing
H13 Tooling
Impeller
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Six Inch Tall Thin Walled Part Substrate Included in Part
Housing Finished Housing11/11/2013 21PSaha
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ToolingPartsbyLENSProcessg y
Injection Molding Injection Mold CavityInjection Molding Core
Injection Mold Cavity
Conformal Cooling Channel
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ToolingPartsbyLENSProcessg y
Trimming DieTrimming Die
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Insuchaninjectionmold,ah d l lhardtoolsteelmaybeselectivelyplacedinregionsh i whereexcessive
wearwouldbeanissue,yetthebulkofthemoldcouldofthemoldcouldbemadeofamaterialwithabettercoefficientbettercoefficientofthermalconduction.)
Injectionmoldingdies(coreandcavity,CADimageandFinalj g ( y, gfabricatedparts)withcopperchillerblockandthreedimensionalconformalcoolingchannel.11/11/2013 24PSaha
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ProcessessimilartoLENSProcess
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C ll d M l B ild UP (CMB)ControlledMetalBuildUP(CMB)(Developed at Fraunhofer IPT, Aachen Germany)(DevelopedatFraunhofer IPT,AachenGermany)
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Di M l D i i (DMD)DirectMetalDeposition(DMD)(Developed at University of Michigan, USA)(DevelopedatUniversityofMichigan,USA)
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Comparison of Direct MetalComparisonofDirectMetalFreeformProcesses
Process Deposition Type Accuracy Horizontal
Layer Thickness Deposition Rate Materials
SLS L i i Hi h N/A N/A S lSLS Laser sintering High N/A N/A Steel, copper, Solder
SDM Droplet based and cladding
N/A, Machined finish
Variable 30g/min Stainless steel, INVAR
Welding Welding 0.2-0.5 mm Up to 50 mm N/A, High Steels, Numerous
Droplet based freeform fabr
Droplet based N/A N/A 25-150 m dia. droplets
Bi-Sn
LENS Cladding 0.02mm, Z: 0 4mm
0.13-0.38 mm N/A, Low SS, Ti alloys, Numerous0.4mm Numerous
DLF Cladding 0.075-0.125 mm 0.075-0.125 mm 1-2g/min SS, P20, Numerous
DMD at Michigan Cladding N/A 0 254 mm 0 1 4 1 cm3/min H13 AlDMD at Michigan Cladding N/A 0.254 mm 0.1-4.1 cm3/min H13, Al, Numerous
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