NEWS Hybrid cladding cuts processing costs
Researchers have developed a hybrid additive manufacturing process that combines wire- based and powder-based laser material deposition (LMD), also known as cladding. The process is significantly
more cost-effective than a pure powder process, while offering greater material flexibility than a pure wire process. In LMD, a laser beam focuses on the component surface while a filler material – usually a powder or wire – is fed and melted. LMD is well suited for applying protective coatings to heavily stressed components, repairing damaged areas and changing workpiece geometry. Fraunhofer IPT scientists,
together with the partners of the MatLaMed project, have developed a hybrid LMD process in which wire and powder are processed simultaneously. The partners say the tool coatings produced using the process are more wear-resistant, resource- efficient and cost-efficient than those from other methods. They plan to use it in a variety of applications, such as the machining of forming tools or the treatment of friction wear layers of hydraulic components. By combining wire and
powder, they are able to flexibly adjust the material composition – and thus the applied coating properties – with each application of the process. ‘With the new process, we
can now respond quickly and flexibly to different thermal, chemical and mechanical loads, as we can adjust toughness and hardness with pinpoint accuracy,’ said project manager Marius Gipperich. In developing the process,
the scientists tested numerous materials. For the wire, these included a hot-work tool steel with good structural stability and a low-alloy steel that can be welded well. For the powder, chromium was used as a carbide-forming and grain-refining element, while
titanium carbide was used as a hard phase. Even the addition of small amounts of titanium carbide led to coating hardness increases of up to 30 per cent. Positive results have provided
the researchers with a basis to develop the hybrid LMD process and imbue other material systems with special properties. Currently they are testing
possibilities for using the process in the production of graded coating systems. They want to increase the titanium carbide content of the material mixture as much as possible.
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AUTUMN 2021 LASER SYSTEMS EUROPE 5
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