Laser cladding for 3D deposition and Free-form repair

Abstract

This paper presents the design and development of a cladding setup for free form laser deposition. Free-form laser deposition can be used for 3D printing of metal parts, repair of high value components and wear resistant surface coating with minimal damage to the existing features, because the heat affected zones and dilution of melt pool into the substrate are controlled. The material for deposition is metal powder. To avoid oxidation of powder during melting and fusion, it is imperative to shield, therefore the powder is mixed with an inert gas. The mixing also increases the flow-ability of the powder and helps in generating a uniform clad. We have designed a powder delivery system and this powder delivery system has been integrated with a 100 W laser, focusing optics and a positioning system for the design of the cladding setup. The experimental setup is able to produce free form clads in two and three dimensions with a consistent quality, using a low power (100 W) laser as compared to traditional setups with high power lasers (2-3 kW).