Improving laser cladding productivity with ‘ABA’ cladding

Koti, Daniel; Powell, John; Voisey, K.T.

doi:10.1016/j.procir.2022.08.048

Cited by 7 publications

(1 citation statement)

References 14 publications

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“…Three cladding techniques were compared: single track cladding ("A" cladding), standard, overlapping track cladding (AAA cladding), and a recently developed technique called ABA cladding. 6,7 These three techniques are described in Fig. 1.…”

Section: Introductionmentioning

confidence: 99%

Laser cladding: A high-speed-imaging examination of powder catchment efficiency as a function of the melt pool geometry and its position under the powder stream

Koti,

Powell,

Naesstroem

et al. 2023

Journal of Laser Applications

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This paper provides quantitative information about the paths taken by blown powder particles during laser cladding. A proportion of the powder is “wasted” by bouncing off the solid areas surrounding the melt pool. This wastage reduces the productivity and profitability of the process. In this paper, specially developed software was used to analyze high-speed imaging videos of the cladding process, to monitor the directions of powder particle flight toward and away from the melt pool area. This information has been correlated to the geometry and position of the melt pool zone for three different cladding techniques: single track cladding (A tracks), standard overlapping track cladding (AAA cladding), and a recently developed technique called ABA cladding. The results show that the melt pool geometry, and particularly the overlap between the melt pool and the incoming powder stream, has a strong influence on powder catchment efficiency. ABA cladding was found to have considerably better powder catchment efficiency than standard AAA cladding and this improvement can be explained by consideration of the geometries and positions of the melt pools and surrounding solid material in each case. As powder costs are an important factor in industrial laser cladding, the adaption of the ABA technique, and/or control of pool/powder stream overlap (e.g., by making the powder stream not coaxial with the laser beam), could improve the profitability of the process.

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Section: Introductionmentioning

confidence: 99%

Laser cladding: A high-speed-imaging examination of powder catchment efficiency as a function of the melt pool geometry and its position under the powder stream

Koti,

Powell,

Naesstroem

et al. 2023

Journal of Laser Applications

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Enhancing productivity and efficiency in conventional laser metal deposition process for Inconel 718 – Part II: advancing the process performance

Maffia,

Chiappini,

Maggiani

et al. 2023

Int J Adv Manuf Technol

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This paper is the second part of a work focused on optimizing the performance of conventional Laser Metal Deposition (C-LMD) process for Inconel 718 (IN718). In Part I, through an extensive experimental campaign on single tracks, the interplay between process parameters and their impact on the deposition rate, powder catchment efficiency, and clad geometry is examined. The parameters investigated include laser power, scan speed, powder feed rate, and standoff distance. By systematically adjusting these parameters, the aim is to identify optimal conditions that maximize productivity while maintaining a favorable clad shape for multi-pass multi-layer depositions. Part II starts from the findings and results of Part I by continuing the optimization on thick wall structures. These are utilized to assess the effect of 3D geometrical process parameters, specifically hatch spacing and Z-step, on process performance and stability. Based on the findings, further optimization procedure is presented, pushing the boundaries of the C-LMD process for IN718. By fine-tuning the process parameters, the capability of the C-LMD process to deposit fully dense IN718 with a productivity of 1500 g/h and a powder catchment efficiency of 70% is demonstrated. These results highlight the potential of C-LMD as a viable manufacturing technique for efficiently fabricating large components. Overall, this study contributes to a deeper understanding of the relationship between process parameters and performance in C-LMD for IN718. The insights gained from this research can guide the development of efficient and cost-effective LMD strategies, facilitating the practical implementation of this process in various industries.

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Bending behaviour of surface corroded and perforated corroded steel tubes repaired by laser cladding additive manufacturing

Kang,

Song

2024

Thin-Walled Structures

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Improving laser cladding productivity with ‘ABA’ cladding

Cited by 7 publications

References 14 publications

Laser cladding: A high-speed-imaging examination of powder catchment efficiency as a function of the melt pool geometry and its position under the powder stream

Laser cladding: A high-speed-imaging examination of powder catchment efficiency as a function of the melt pool geometry and its position under the powder stream

Enhancing productivity and efficiency in conventional laser metal deposition process for Inconel 718 – Part II: advancing the process performance

Bending behaviour of surface corroded and perforated corroded steel tubes repaired by laser cladding additive manufacturing

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