1. No category

Metallipinnoitus –
pinnoitusmenetelmien
mahdollisuudet ainetta
lisäävässä valmistuksessa
J. Tuominen
Tampereen teknillinen yliopisto
Materiaaliopin laitos
Laser Application Laboratory
Sisältö
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•
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Yleistä pinnoitusmenetelmistä
Laserpinnoitus
– Jauhe
– Lanka
– Hybridimenetelmät
– Kaupalliset laitteet & sovellukset
– Materiaalit
– Komponenttien ominaisuudet
Päällehitsaus kaarimenetelmillä
– CMT
• Fusion bond
• Low dilution (single layer)
• Terminen ruiskutus
– Kylmäruiskutus
• Edut, rajoitukset
• Yhteenveto
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Classification of coating methods
Energy from:
• High intensity light
kJ/m2:
Moder
• Combustion gases Low
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• Kinetic energy
Low
• Electric arc
High
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Surface engineering
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§
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Composite solution
Sustainable
Material efficient
Global cladding/overlay welding
markets expected to rise from 3.8 to
7.6 billion USD by 2015*
* Abakan Inc.
Global thermal spraying markets
were 7.1 billion Eur in 2011*
* The Linde Group
, cladding
Global market for AM will
reach 3.5 billion USD by
2015*
* Wohlers report
”Let there be light”, Genesis 1:3
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Principle of laser cladding
Feedstock material (coating
material in the form of
powder, wire or strip) is fed
to the melt pool created by
laser beam
Thin layer of base material
is melted, which provides
fusion bond, low dilution,
dense clad layer with
excellent properties
Several layers on top of
each other -> 3D printing
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Laser cladding methods
Powder and
carrier gas
Powder and
carrier gas
Laser
beam
Laser beam
Shielding gas
Clad layer
Shielding gas
Clad layer
Substrate
2-step: preplaced powder
1-step: off-axis hot-wire (tandem)
1-step: off-axis powder
1-step: coaxial cold-wire
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Substrate
1-step: coaxial powder
1-step: coaxial hot-wire
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Industrial laser cladding &
applications
1-step: coaxial powder
On-site cladding
§ Metallic and MMC coatings on metallic
base materials
§ Main benefits:
§
Fusion bond
§
Low dilution
§
Low distortion
§ Industrial cladding with 3-6kW lasers
& powder feedstock:
§
Low deposition rates (1-2 kg/h)
§
Low material efficiency (~70%)
§ New components / Remanufacturing
(50/50)
ID cladding
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High power laser cladding
§ Inconel 625: 15 kW, 1 m/min, 15 kg/h (500 mm3/s)
§ New world record!!!
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Induction assisted laser cladding
Without induction
With induction
Stellite 12 on M238 mould steel (646 x 230 x 196 mm3)
Fully closed-loop cladding process
J. Tuominen, TUT
Stellite 20 on
AISI 1045
F. Brückner,
Fraunhofer
IWS
Chromalloy Gas Turbine Corp, USA
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Laser cladding cell
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Process variables affecting the
outcome
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Kaupalliset laitteet (jauhe)
HC-254 (Huffman)
LENS 850-R (Optomec Inc.)
EasyCLAD (BeAM)
§
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§
§
§
§
§
§
DMD 505 (DM3D Inc.)
RPM’s 557 (RPM
Innovations Inc)
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§
§
1 – 5 kW fiber, disc or diode laser
5-axis CNC machine
Several powder hoppers
Working volume 900 x 1500 x 900 mm3
Max component weight 200 – 300 kg
Controlled atmosphere (O2≤10ppm,
H2O<50ppm)
Closed-loop process control
Software to create tool path from 3D CAD
data
Powder is recycled
Track width 0.5 – 5 mm
Up to 50 mm3/s
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Yhdistelmäkoneet (AM + subtractive)
DMG Mori: Lasertec 65 3D
Optomec Lens + Fadal CNC mill
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Yhdistelmäkoneet (AM + subtractive
+ laser microprocessing)
Laser marking
MAZAK INTEGREX i-400AM
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Yhdistelmäkoneet (AM + subtractive
+ inspection with touch probe +
laser microprocessing)
Hybrid Manufacturing Technologies
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Sovellusesimerkkejä
Pituus 600 mm
Airfoil (siipiprofiili)
Inconel 625
NRC-CNRC
Laskutelineen osa
Ti6Al4V alloy
AeroMet Corp.
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Sovellusesimerkkejä
Efesto
DMG Mori
Aihio
Suorakerrostus
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Jälkityöstö
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Sovellusesimerkkejä
Manufactured by DMD
method
Hip implant manufactured by
LENS method
Ti alloy
Femoral component
Manufactured by DMD
method
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Materiaalit
• Hardfacing alloys (Stellites, Tribaloy, Norem, Nanosteel, Self-fluxing alloys,
Nistelle, Nucalloy)
• Superalloys (Inconel, Hastelloy, Monel, CMSX-4, high-Cr NiCr)
• Tool steels (P20, M4, H13, CPM 10V)
• Stainless steels (316L, 254SMO, 420, 17-4 PH, duplex)
• Hadfield-steels (12-19%Mn, 1.1-1.4%C, 0-2.5%Cr )
• Titanium alloys (Ti-6Al-4V, Ti6242, Ti grade 2)
• Copper alloys (CuAl, CuNi, CuSn)
• Aluminium alloys (AlSi5 (4043), AlSi10Mg, AlSi12, AlSi7Mg)
• Metal matrix composites (WC/W 2C-NiCrBSi, TiC-Stellite, VC-tool steel, SiC-Al,
synthetic diamonds)
• Solid lubricants (MoS2, WS2, CaF2, graphite)
• Intermetallics (Cr13Ni5Si2, MoSi2, FeAl, NiTi)
• Gradient layers (FGM) (metal matrix composites, monolithes)
• Nanostructured and amorphous alloys, intelligent materials
• High entropy alloys (development of new alloys)
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IN-625 microstructure
Lähde: IMTI National Research Council Canada
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Mechanical properties (static)
§ Complex thermal history (directional heat extraction, repeated melting & rapid solidification, repeated solid
state transformations)
§ Reduced grain size due to high solidification rates
§ Directionally solidified structures
§ Anisotropic mechanical properties
Lähde: IMTI National Research Council Canada
Lähde: IMTI National Research Council Canada
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Mechanical properties (dynamic)
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Corrosion resistance
§ High cooling rates
reduce partitioning
§ Corrosion properties
close to wrought alloys
and better than cast
structures
Lähde: IMTI National Research Council Canada
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Dimensional accuracy & surface
finish
Lähde: IMTI National Research Council Canada
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Laser wire cladding & additive
manufacturing
University West, Trollhättan
§ Main benefits over powder:
Material efficient (100%)
§ Clean
§ Possible to heat by resistive heating
§ Chemically cleaner feedstock
§ Less contamination during processing
§ Cheaper than powder
§ Tubular wires more challenging
§
Fraunhofer IPT, Aachen
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Coaxial wire laser cladding &
additive manufacturing
Precitec
Mitsubishi
Cavipro
Fraunhofer IWS
HighYAG/IWS
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Coaxial hot-wire laser cladding &
additive manufacturing
Duplex: 3.5kW, 4m/min, 250A, 7V, 5kg/h (150 mm3/s)
§ Main benefits:
§
§
§
§
§
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High process stability
Less parameters in wire
alignment
Omni-directional
Increased productivity
Material efficient
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Examples of laser wire
manufactured parts
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Laser + arc hybrid cladding &
additive manufacturing
Arc between
two wires
1.4718 steel, 63 HRC
Laser + MIG/MAG, single wire
Twin wire 10kg/h
1.8401 steel, 38 HRC, 2 kg/h
§ Main benefits:
§
§
§
Mild steel
§
§
1.8401 steel
§
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Low dilution
Low heat input
Increased productivity
Low power capacity laser
source (<500W)
Stabilization & guidance
of electrical arc by laser
More stable process
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Kaupalliset laitteet (EB lanka)
Sciaky Inc.
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§
§
§
Working space 5791 x 1219 x 1219 mm3
Deposition rate 3 – 9 kg/h
Titanium, Tantalum, Inconel, Stainless steels
Closed loop process control
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Cold metal transfer (CMT) cladding &
additive manufacturing
§
§
§
§
§
§
§
Advanced MIG
High speed digital control
Wire retracted at up to 140Hz
Wire motion directly incorporated to
electrical contol
Max I = 280 A
Solid wires up to Ø1.2mm
Tubular wires up to Ø1.6mm
§ Main benefits:
§
Single wire, ~5kg/h
Twin wire, ~10kg/h
§
§
§
§
§
§
§
§
§
§
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Low dilution
Low heat input
High productivity
Material efficient
Energy efficient (wall-plug, process)
Power by aggregate
On-site eligible
ID cladding, Ø>100mm
Low investments
No optical elements
Low safety precautions
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Cold metal transfer (CMT) cladding &
additive manufacturing
Alloy 625
Refuse incinerators and power stations
Boiler walls and pipes (coal, waste, biofuel) (400-550°C)
Turbine rotors (hydropower)
Ship propellers
Mould repair
Alloy 625
Valves
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Cold metal transfer (CMT) additive
manufacturing
α-Al primary dendrite (light)
Al/Si
eutectic
(dark)
4.1 mm
50 HV0.05
11 µm
Transverse cross-section of AlSi5 build-up
Al
Ra 3.0µm
Si
40 mm3/s
150 layers
Hypoeutectic AlSi5 (4043) by robotguided CMT process
15 µm
Elemental maps of Al and Si
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Sovellusesimerkkejä
Cranfield University
Steel/bronze
Cranfield University
Pelton runners for hydropower
stations
Cranfield University
Stiffened panel / Aluminium
Cranfield University
Cranfield University
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Suorakerrostus vs. jauhepeti
Ominaisuudet
Suorakerrostus
Jauhepeti
Materiaalit
• laaja materiaalivalikoima
• jauhe, lanka
• rajoittunut
(materiaalvalikoima kasvaa
nopeasti)
Kappaleiden koko
• kappaleiden/suutinpään
käsittelyjärjestelmä rajoittaa
• prosessikammio rajoittaa
Kappaleiden
monimutkaisuus
• rajoittunut
• lähes rajoittamaton
Tarkkuus
≥ 0.5 mm
≥ 0.1 mm
Tuotto
– 150 mm3/s
– 20 mm3/s
Alusta
• 3D-pinta
• aihio
• tasainen pinta
• tasainen aihio
Pinnankarheus Rz
60 – 100 µm
10 – 50 µm
Kerrosten paksuus
≥ 0.1 – 2 mm
≥ 0.015 – 0.1 mm
Tukirakenteiden
tarve
Ei
Kyllä (ulkonemat)
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Terminen ruiskutus muodonantomenetelmänä
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Additive manufacturing by cold spray
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Ref. Peter Richter Jr, Advanced High
Pressure Cold Spray
Innovative Technology „Playground“,
North American Cold Spray
Conference, Canada, 2014
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Coaxially laser assisted cold spray
COLA (http://www.cola-project.eu/, The European Union 7th Framework Programme ):
new, cost-effective laser-assisted cold-spray technique, for high-quality
deposition and repair
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Yhteenveto
• Metallien 3D-tulostukseen soveltuvia pinnoitusmenetelmiä ovat:
– Laserpinnoitus
– Päällehitsaukseen soveltuvat kaarihitsausmenetelmät (kylmäkaari)
– Terminen ruiskutus (kylmäruiskutus)
– Hybridimenetelmät (laserkuumalanka, laser+kaari, laser+ruisku, laser+induktio)
• Jauhepetimenetelmään verrattuna:
– Suurempi tuottavuus (isommat kappaleet)
– Muodonanto jo olemassa olevaan kappaleeseen, korjaus
– Mahdollisuus yhdistää ainetta lisäävä ja poistava valmistus (esi-, väli-,
loppukoneistus)
– Tukirakenteiden tarpeettomuus
– Adaptiivinen prosessinsäätö
– Alhaisempi resoluutio ja mittatarkkuus
– Alhaisempi pinnanlaatu
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