LASER MACHINING
metal powder is applied to a substrate plate and then a 200- W laser is used to fuse the cross section of the geometry to the plate. After the exposure the plate is lowered and the next layer of powder is applied. This procedure is repeated until the part is fi nished. The entire process takes place inside the enclosure, blanketed by protective gas, and at an oxygen content of 0.1% for maximum part quality. To apply high volumes of metal at high deposition rates,
Trumpf continues to develop its LMD technology, which is well-suited for adding volume and structures/features to existing parts. In LMD systems, the laser forms a melt pool on the surface of a component and fuses the powder—ap- plied simultaneously and coaxially—to create the desired shape. Applying multiple layers enables the user to expand the form in any direction. With the ability to add material at rates as great as 500 cc/hour, this process can be more economical than conventional manufacture. In addition, complex structures can be added to existing parts allow- ing for the design of common base structures that have features and strength added where needed. Based on the specifi cs of the application, fabricators can choose either the large TruLaser Cell 7040 or the more compact TruLaser Cell 3000 with the new LMD package.
Improved Process for Laser Welding Aerospace Alloys Prima Power Laserdyne (Champlin, MN) has introduced
improved process parameters for laser welding nickel-based aerospace alloys to meet stringent airframe and aero-engine requirements. High-quality butt and lap joint weld are pos- sible and practical in a number of common nickel-based aerospace alloys following guidelines established by Laser- dyne applications engineers. Here’s how Prima Power Laserdyne describes the
improved process. Using Prima Power Laserdyne’s Smart- Ramp, which makes use of Laserdyne S94P laser and motion control, weld dimensions on both the top and bottom sides of the weld—with or without fi ller metal—are controlled with no observable porosity within the weld fusion zone. Integrated laser and motion control with the Laserdyne S9P laser process control enables production of crack-free welds through use of laser process parameters that take into ac- count the relatively large solidifi cation temperature range of nickel-based aerospace alloys and the fact that brittle phases can form when solidifi cation rates are low. Joint cleaning to remove contaminants before welding nickel-based aerospace alloys is essential. At high tem-
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November 2016 |
AdvancedManufacturing.org 57
peratures, nickel alloys are susceptible to embrittlement from sulfur, phosphorus, lead, and other low-melting point substances that are often present in materials used in every- day manufacturing processes. Typical contaminants include grease, oil, paint, cutting fl uids, marking crayons and inks, machine lubricants and lacquers. Correct fi xturing to control thermal expansion during weld- ing is similarly important. The thermal expansion characteris- tics of nickel-based aerospace alloys are similar to those of carbon steel. When welding, the forces and distortion gener- ated by both materials are similar and require component restraint by a properly designed holding fi xture. The restraint provided can be used to control stress in the weld. For example, if an appropriate clamping force is used to restrain the material near the weld joint, the expansion created in the weld joint will lead to a compressive force in the weld. This compressive force will in turn lead to upsetting of the weld metal and corresponding reinforcement, or crown , of the top and bottom of the weld, even without fi ller metal.
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