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Using wire shaping techniques and holographic optics to optimize deposition characteristics in wire-based laser

N J Goffin1, R L Higginson2, J R Tyrer1

  • 1Wolfson School of Mechanical, Electrical and Manufacturing Engineering , Loughborough University , Loughborough, LE11 3TU , UK.

Proceedings. Mathematical, Physical, and Engineering Sciences
|January 26, 2017
PubMed
Summary

Wire shaping in laser cladding improves control and quality, overcoming powder-based limitations. This technique enhances deposition rates and enables the creation of dense, 3D structures with uniform properties.

Keywords:
dilutionholographic opticslaser claddingpower densitywire shaping

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Area of Science:

  • Materials Science and Engineering
  • Additive Manufacturing
  • Laser Processing

Background:

  • Laser cladding typically uses powder, facing issues like gas entrapment and low density.
  • Wire feeding in laser cladding offers superior quality but is difficult to control, limiting its industrial adoption.
  • Existing wire-based methods are often considered academic due to control challenges.

Purpose of the Study:

  • To investigate wire shaping techniques combined with holographic optical elements to enhance laser cladding processing.
  • To improve control, deposition rate, and quality consistency in wire-based laser cladding.
  • To explore the potential for creating advanced 3D structures using shaped wire.

Main Methods:

  • Experiments utilizing pre-placed wire, comparing standard round wire with shaped wire (specifically flat wire).
  • Investigation of wire shaping effects on melting uniformity, power density, and clad track dilution.
  • Evaluation of clad track quality consistency and sensitivity to processing condition variations.
  • Assessment of multi-layer stacking for 3D structure fabrication.

Main Results:

  • Shaped wire provided uniform melting, reducing power density needs and improving clad track dilution control.
  • Flat wire feeding resulted in enhanced quality consistency and reduced sensitivity to processing changes.
  • A significant 22% increase in deposition rate was achieved with shaped wire.
  • Stacked layers successfully formed fully dense, 3D structures exhibiting directional grain growth and uniform chemical composition.

Conclusions:

  • Wire shaping is a viable technique to significantly improve the control and processing characteristics of wire-based laser cladding.
  • This approach overcomes key limitations of powder-based cladding, offering superior quality and efficiency.
  • The method enables the fabrication of high-quality, dense, multi-layered 3D structures with controlled microstructures.