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EWI’s Laser Equipment

4-way beam switch. 15-kW Laser. EWI’s Laser Equipment. 15-kW IPG Fiber Laser. Laser Optics for Broad Coverage. Off-the-shelf integrated focusing optic Integrator lens with 6- × 8-mm rectangular spot. Beam shape on thermoplastic burn block. Integrator Lens. Beam shape on burn paper.

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EWI’s Laser Equipment

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  1. 4-way beam switch 15-kW Laser EWI’s Laser Equipment • 15-kW IPG Fiber Laser

  2. Laser Optics for Broad Coverage • Off-the-shelf integrated focusing optic • Integrator lens with 6- × 8-mm rectangular spot Beam shape on thermoplastic burn block Integrator Lens Beam shape on burn paper

  3. Broad Process Setup • Powder delivery system • Fiber optic delivery • Laser head • Integrator lens • Custom power nozzle • Powder delivery line

  4. Samples Stainless to Steel Inconel (2 pass) Stellite to Steel

  5. Dilution • Dilution typically less than 5% L2 L1 A1 A2 A3 ~2.6% Dilution 6 mm

  6. 10-kW Fiber Laser • 316L on 4130 • 9- × 12-mm rectangular spot • 8 kW • ~1 mm build-up (single pass)

  7. Submerged Arc Strip Cladding SASC • Typically 750 A, up to 40 lb/hr Typical dilution of 10-20%

  8. Electroslag Strip Cladding • ESC - Typically 1400 A, up to 60 lb/hr, dilution 5-15%

  9. Additive Manufacturing (AM) – An Extension of Cladding • From single beads stacked upon each other (bottom) • To large features at high deposition rates (top) • Mitigated by balance of net-shape, metallurgical requirements, mechanical properties (tensile, fatigue, etc.)

  10. AM – Progressive Layers • Additive manufacturing - build in layers, stress relieve/PWHT, machine, as/if necessary

  11. Increased Deposition Rate Decreased Resolution Deposition Rate vs Resolution Courtesy Boeing

  12. Summary • Surface engineering is a broad field ranging from ion implantation to explosive cladding in terms of the mass of material deposited in unit time. • Practical methods for powder and strip cladding areas large and small, across a range of industries, include fusion-based processes such as GTA, PTA, GMA, laser, SASC, and ESSC depending on the area to be clad, deposit thickness, and chemistry required. Others include thermal spray, e.g., HVOF. • Many processes require two layers to achieve the desired surface chemistry and corrosion resistance; others require only one layer.

  13. Questions? Ian D. Harris Technology Leader, Arc Welding Email: iharris@ewi.org Phone: 614.688.5131

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