CLADDING AND ADDITIVE MANUFACTURING USING LASER APPLIED POWDER ® PROCESSES CLADDING AND ADDITIVE MANUFACTURING USING LASER APPLIED POWDER ® PROCESSES AWS New Welding Technologies June , 2010 Salay Stannard AWS New Welding Technologies June , 2010 Salay Stannard

Who Is Joining Technologies? About 60 employees 25,000 SF, With Room to Expand At Current Location 2,000 SF Dedicated to Laser Cladding Laser Applied Wire (LAW®) Additive Processing Laser Applied Powder (LAP®) Additive Processing Laser Welding EB Welding GTAW Lasers Systems Design & Integration Supply Chain Management ISO 9001:2000 AS9100 NADCAP Certified for Welding

The Necessity for Component Repair and Surfacing Technologies Why repair technologies are needed: Wear and Damage Sealing Surfaces Mounting / Fretting Surfaces Bearing and Loaded Surfaces Tools and Dies Manufacturing Nonconformities Under filled castings Incorrect Machining Design Changes High Value Parts Long Lead Times

Laser Based Repair Technologies Pulsed Wire Cladding CW Laser Wire Cladding Laser Blown Powder Cladding

Pulsed Laser Wire Cladding Wire is positioned on top of substrate Wire is stationary relative to part Laser fuses wire to substrate by a series of spot welds Manual or automated processing Manual process is well suited to limited production or highly irregular repairs Not well suited to crack sensitive materials due to rapid heating and cooling rates Low deposition rates due to low average laser power, limited pulse rate and need to synchronize wire and part feed

Continuous Wave (CW) Laser Wire Cladding Laser beam creates molten pool on part Filler wire is fed into pool by precision wire feed Wire is melted and incorporated into the pool to create a bead Process is nearly always automated Better for crack sensitive materials ~ 10x higher deposition rates than pulsed wire

Laser Powder Cladding Laser beam creates molten pool on part Metal powder is blown into pool by precision powder feed system Powder is melted and incorporated into the pool to create a bead Process is always automated Largest selection of available clad materials ~ 10x higher deposition rates than CW wire feeding

Blown Powder Nozzle SchematicMultijet NozzleCoaxial Nozzle Laser Powder Cladding

Need for Cladding and Additive Manufacture Aerospace Power Generation Oil/Gas

Special Challenges in Aerospace Processing Process: Limited industry specifications FAA & OEM barriers Limited to repair and design work Document/Control Stringent metallurgical requirements Minimal heat input required Poor capture rate: 30-40% detail, 12-20% knife edges Machine cannot be modified after source approval Test pieces are rare due to high cost of part Need: Overhaul and Repair

Special Challenges in Power Generation Longer processing times for large part surface areas JT: 9.6lb/hr approx 90% capture Part geometry varies job to job Less stringent on powder quality Open metallurgy requirements Accepting of ↑HAZ, dilution, etc. Need: Hard facing, corrosion resistance

Special Challenges in Oil/Gas Longer processing times for large part surface areas Less stringent on powder quality Accepting of ↑HAZ, dilution, etc. Need: Hard facing, corrosion resistance, wear resistance

Work Cell for Aerospace Processing Platform: Cartesian CNC preferred Beam quality is important Solid-state systems -Disk or fibre lasers JT: 2kW → 4kW Trumpf disk laser Clad Requirements: Powder- Rotary vs. Atomized Quality is critical! Accepting of additive with wire Typical repair thickness < 0.060” Materials deposited include: Stellite 6, 21 SS410, 410L IN 100 Inconel 625,

Work Cell for Power Generation Processing Platform: Flexible beam quality, direct diode systems possible 3 -7mm spot size Coaxial system, He powder delivery Clad requirements: Typical thickness 0.040” – 0.200” JT: deposited 0.040” – 3+” HRc, > 45 HRc cracking possible with carbide powders Materials deposited include: Inconel 622, 625, 718 Carbides Stellite 6, 21 Ni-Cr Tool Steels

Work Cell for Oil/Gas Processing Platform: Flexible beam quality, direct diode systems possible 3 -7mm spot size Coaxial system, He powder delivery Clad requirements: Typical thicknesses 0.040” – 2” > 0.080” cracking possible Materials deposited include: Carbides Ni-Cr Inconel 622, 625, 718 Stellite 6, 21 WC-Cr WC-Co-Cr

Advantages of Powder vs. Wire Laser Wire Cladding Welding with wire is a well established aerospace process Typically lower capital investment than for powder Crack and pore free deposition is attainable for many common aerospace materials using commercially available wire 100% utilization of filler material Laser Powder Cladding: Higher maximum deposition rates Larger variety of possible clad materials Processing head is compact, omnidirectional and completely non contact Minimum feature size and heat input are limited only by minimum laser focus size and economics Lower dilution

LAW ® Work Cell Equipment Designed and built by Joining Technologies Trumpf TruDisk 1000 Laser supply 3- Axis CNC control with rotary Wire 0.010” – 0.025” diameter Closed loop servo controlled wire feed Real time power density control while welding Non contact profile scanning with data storage Highly efficient wire placement algorithms Vision based wire tracking within 0.003” Real time work piece temperature control

Trumpf TruDisk 4002 (4kW) Laser Supply KUKA KR 30/HA (High Accuracy) Robot Approx. 6ft radius hemisphere range 66lbs. payload KUKA DKP Rotary/Tilt Table Approx. 880lbs. load Programmable Dual Powder Feeders On the Fly Focus spot size control Multi-jet or Coaxial powder delivery LAP ® Work Cell Equipment

Equipment Acquisition August installation of Trumpf 505 Powder Cladding system 6kW CO 2 Laser 6.5ft X 3.2ft X 2.5ft envelope 5 Axis motion platform High capacity rotary Programmable spot size High absolute and relative accuracy Two hopper powder feed

Lab Expansion and LAP ® Upgrade Additional 10,000 sq ft cladding workspace Accommodations for parts up to 3ft dia x 40ft long x 5 tons 30ft linear rail for robot positioning Multi-ton capacity precision head stock, tail stock and steady rests

Both laser additive technologies, wire and powder, have many overhaul and repair applications for the aerospace, power generation, and oil/gas industries. When compared to traditional repair processes additive manufacturing maintains base metallurgy with low heat inputs and a high degree of control. Industry acceptance remains a challenge, but is sure to improve with continued research, development and testing.

Salay StannardProcess Development Scott PoeppelManager of Additive Dave HudsonPresident Visit for a detailed list of capabilities and to sign up for our industry video blog