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- Additive manufacturing (2)
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- Cladding parameter (1)
- Design of experiments (1)
- Laser cladding (1)
- Laser metal fusion (1)
- Repair welding (1)
- Turbine blade (1)
Laser beam processes are increasingly used in the field of additive manufacturing.
Prominent methods are either powderbed-based like Laser Metal Fusion (LMF), or utilizing a powder nozzle like Laser Metal Deposition (LMD). While LMF allows the manufacturing of complex structures, build rate, part volumes and material flexibility are limited. In contrast, LMD is able to operate with high deposition rates on existing parts, and materials can be changed easily during the process. However LMD shape complexity is limited. Utilizing their respective strengths, a combination of these two additive technologies has the potential to produce complex parts with high deposition rates and increased material flexibility. In this paper, combined manufacturing with additive technologies LMF and LMD is described. Its benefit for industry with emphasis on turbomachinery is shown. As reality test for the innovation, an industrial turbine blade is manufactured.
The process of laser metal deposition can be applied in many ways. Mostly, it is relevant to coating, for repair welding and for additive manufacturing. To increase the effectiveness and the productiveness, a good process understanding is necessary. Statistical test planning is effectual and often used for this purpose. For financial and temporal reasons, a restriction of the test space is reasonable. In this case, it is recommended to use a D-optimal experimental design which is practically applied to extend existing test plans or if process Limits are known. This paper investigates the applicability of a D-optimum experimental design for the laser metal deposition. The results are compared to the current results of a full factorial test plan.
Known restrictions are used for the limitation of the test space. Ti6Al4 is utilized as Substrate material and powder. Comparable results of the D-optimal experimental design and of the full factorial test plan can be demonstrated. However, 80 % of time can be saved by the experimental procedure. For this reason, the application of D-optimal experimental design for laser metal deposition is recommend.