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EWI’s Laser Equipment
15-kW IPG Fiber Laser
4-way beam switch
15-kW Laser
Laser Optics for Broad Coverage
Off-the-shelf integrated focusing optic Integrator lens with 6- × 8-mm rectangular spot
Beam shape on thermoplastic burn block
Beam shape on burn paper
Integrator Lens
Broad Process Setup
Fiber optic delivery
Laser head
Integrator lens
Custom power nozzle Powder
delivery line
Powder delivery system
Samples
Stainless to Steel
Stellite to Steel
Inconel(2 pass)
Dilution
6 mm
L1
L2
A3A2A1
~2.6% Dilution
Dilution typically less than 5%
10-kW Fiber Laser
316L on 4130 9- × 12-mm rectangular spot 8 kW ~1 mm build-up (single pass)
Submerged Arc Strip Cladding SASC
Typically 750 A, up to 40 lb/hr Typical dilution of 10-20%
Electroslag Strip Cladding
ESC - Typically 1400 A, up to 60 lb/hr, dilution 5-15%
Additive Manufacturing (AM) – An Extension of Cladding From single beads
stacked upon each other (bottom)
To large features at high deposition rates (top)
Mitigated by balance of net-shape, metallurgical requirements, mechanical properties (tensile, fatigue, etc.)
AM – Progressive Layers
Additive manufacturing - build in layers, stress relieve/PWHT, machine, as/if necessary
Deposition Rate vs ResolutionCourtesy Boeing
Decreased Resolution
Incr
ea
sed
De
po
sitio
n R
ate
Summary
Surface engineering is a broad field ranging from ion implantation to explosive cladding in terms of the mass of material deposited in unit time.
Practical methods for powder and strip cladding areas large and small, across a range of industries, include fusion-based processes such as GTA, PTA, GMA, laser, SASC, and ESSC depending on the area to be clad, deposit thickness, and chemistry required. Others include thermal spray, e.g., HVOF.
Many processes require two layers to achieve the desired surface chemistry and corrosion resistance; others require only one layer.
Questions?Ian D. HarrisTechnology Leader, Arc WeldingEmail: [email protected]: 614.688.5131