Distortion and Dilution Behavior for Laser Metal Deposition onto Thin Sheet Metals

Tebaay, Lennart M.; Hahn, Marlon; Tekkaya, A. Erman

doi:10.1007/s40684-020-00203-9

Cited by 20 publications

(6 citation statements)

References 22 publications

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“…Residual stresses, surface roughness and shape accuracy are the main challenges by using AM for laminated tooling. Residual stresses in additively manufactured parts are not only dependent on the process parameters such as power, feed rate, and mass ow, they also highly depend on scanning strategies, cooling times or dwell time, and the initial temperature of the substrate [17]. Rangaswamy et al [18] showed that the laser rastering direction has an insigni cant effect on the magnitude of the residual stresses of 316L powder.…”

Section: Introductionmentioning

confidence: 99%

Effect of preheating during laser metal deposition on the properties of laminated bending dies

Joghan

Hahn²,

Tekkaya³

2022

Preprint

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Metal laminated tooling provides a fast and cheap manufacturing concept. In this study, laser metal deposition (LMD) is used for reducing and eliminating the stair step effect in a metal laminated bending die. A systematical analysis of the effect of preheating of the laminae on the surface quality and mechanical properties of the bending die is performed. Ferritic steel sheets (S355 MC) with a thickness of 2 mm are laser cut and stacked up to manufacture the laminated bending die with a radius of 6 mm. The sheets are joined and the stair steps are filled with LMD with stainless steel powder 316L-Si. The initial temperature of the tool sheets (substrates), beside room temperature, is elevated up to 300 °C. The effect of the preheating on the surface roughness, shape deviation, hardness, and residual stresses of the die are investigated. The mean height of the surface increases by 59% at elevated temperatures. However, the tensile residual stress parallel to the weld direction at the middle of the deposited area decreases only around 25%. The functionality of the forming tools manufactured by this method is proven by bending of DC06 and HC380LA sheets.

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Section: Introductionmentioning

confidence: 99%

Effect of preheating during laser metal deposition on the properties of laminated bending dies

Joghan

Hahn²,

Tekkaya³

2022

Preprint

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“…Typically, laser cladding is performed on substrates with thicknesses of multiple millimeters, such as cylinders [11,12] or plates [13,14]. The application of laser cladding on thin-sheet substrates was first reported by Burmester et al [15] and has only been scarcely studied in the literature for sheets with a thickness below 10 mm [16,17], as well as below 1 mm [15,18,19]. As the use of high-power, continuous-wave (cw) lasers have yielded excess energy input and distortion, Burmester et al [15] employed a pulsed Nd:YAG-laser to limit the energy input and a chilled clamping device, which allows for cooling of the sheet during laser cladding.…”

Section: Introductionmentioning

confidence: 99%

“…With a focus on solidification and microstructural evolution, a pulsed Nd:YAG-laser was also used by Farnia et al [17] to clad pre-placed Stellite 6 powder on sheets of low-carbon steel. Laser systems operating in cw-mode were first used for cladding of sheet metal by Gabriel et al [18] and Tebaay et al [19]. While Gabriel et al [18] used an ytterbium-fiber laser with powers up to 82 W to clad cobalt-based powder onto Inconel 718 substrates with a thickness of 0.2 mm, Tebaay et al [19] investigated the use of a 2.5 kW diode-laser for cladding of AISI 316L powder on a DC01 sheet in either cold-rolled steel or a condition after incremental sheet-forming.…”

Section: Introductionmentioning

confidence: 99%

“…Laser systems operating in cw-mode were first used for cladding of sheet metal by Gabriel et al [18] and Tebaay et al [19]. While Gabriel et al [18] used an ytterbium-fiber laser with powers up to 82 W to clad cobalt-based powder onto Inconel 718 substrates with a thickness of 0.2 mm, Tebaay et al [19] investigated the use of a 2.5 kW diode-laser for cladding of AISI 316L powder on a DC01 sheet in either cold-rolled steel or a condition after incremental sheet-forming. The use of laser cladding for reinforcement of aluminum [20] or steel sheets [21,22] prior to forming operations has also recently attracted pronounced attention.…”

Section: Introductionmentioning

confidence: 99%

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High-Speed Laser Cladding on Thin-Sheet-Substrates—Influence of Process Parameters on Clad Geometry and Dilution

2021

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Laser-based Directed Energy Deposition (DED-LB) represents a production method of growing importance for cladding and additive manufacturing through the use of metal powders. Yet, most studies utilize substrate materials with thicknesses of multiple millimeters, for which laser cladding of thin-sheet substrates with thicknesses less than 1 mm have only been scarcely studied in the literature. Most studies cover the use of pulsed laser sources, since sheet distortion due to excess energy input is a key problem in laser cladding of thin-sheet substrates. Hence, the authors of the present investigation seek to expand the boundaries of cladding thin-sheet substrates through the use of a high-speed laser cladding approach which utilizes a continuous-wave, ytterbium fiber laser and traverse speeds of 90 mms−1 to clad stainless steel sheets with a thickness of 0.8mm. Furthermore, fundamental process–property relationships for the target values of clad width, clad height, and dilution depth are studied and thoroughly discussed. Additionally, process maps for the target values are established based on manifold experiments, and the significance of process parameters on target values is studied using analysis of variance. The results demonstrate that clad widths as high as 1413 μm and dilution depths as low as 144 μm can be obtained by high-speed laser cladding of thin-sheet substrates. Thus, pathways toward thin-sheet substrates with enhanced performance are opened.

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“…Appreciable advances have recently been made in the fabrication of metal components for applications requiring strict tolerances and high-load capacity [ 1 ]. Success in this area can largely be attributed to the improvements of the powder properties, such as composite structures or engaged nano-particles, in the developed metallic powders to facilitate direct/selective laser melting methods [ 2 , 3 ].…”

Section: Introductionmentioning

confidence: 99%

Effects of Energy Parameters on Dimensional Accuracy When Joining Stainless-Steel Powders with Heterogeneous Metal Substrates

2021

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This work presents some breakthroughs for obtaining high dimensional accuracy and reliable geometrical tolerance in the joining of stainless-steel powders with heterogeneous substrates. In the laser melting process, the interfacial energy fractions and forces acting at the solid–liquid surface of the melting powders can effectively vary their geometrical shapes and positions before they turn into the liquid phase. When the interfacial free energy is low, the melting powders are near molten, thus the successive volumetric changes can alter the layered geometry and positions. This assumption was validated by a powder-bedding additive manufacturing process to consolidate stainless-steel 316L powders (SLM 316L) on a thin heterogeneous stainless-steel substrate. Experiments were carried out to reveal the effects of the process parameters, such as laser power (100–200 W), exposure duration (50–100 µs) and point distance (35–70 µm) on the resulting material density and porosity and the corresponding dimensional variations. A fractional factorial design of experiment was proposed and the results of which were analyzed statistically using analysis of variances (ANOVA) to identify the influence of each operating factor. High energy densities are required to achieve materials of high density (7.71 g/cm3) or low porosity (3.15%), whereas low energy densities are preferable when the objective is dimensional accuracy (0.016 mm). Thermally induced deflections (~0.108 mm) in the heterogeneous metal substrate were analyzed using curvature plots. Thermally induced deformations can be attributed to volumetric energy density, scanning strategy, and the lay-up orientation. The parametric optimizations for increasing in dimensional accuracy (Z1: ~0.105 mm), or in material density (~7.71 g/cm3) were proven with high conversion rates of 88.2% and 96.4%, respectively, in validation runs.

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Distortion and Dilution Behavior for Laser Metal Deposition onto Thin Sheet Metals

Cited by 20 publications

References 22 publications

Effect of preheating during laser metal deposition on the properties of laminated bending dies

Effect of preheating during laser metal deposition on the properties of laminated bending dies

High-Speed Laser Cladding on Thin-Sheet-Substrates—Influence of Process Parameters on Clad Geometry and Dilution

Effects of Energy Parameters on Dimensional Accuracy When Joining Stainless-Steel Powders with Heterogeneous Metal Substrates

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