Laser Metal Deposition (LMD) Toolpaths with Adaptive Capability for Complex Repairs and Coating Geometries

Abstract

Inside Direct Energy Deposition (DED) processes is the Laser Metal Deposition (LMD) technology. Industries that can implement this technology approach are from automotive to energy sectors where critical parts suffer due to operation cycles, weather or hazardous environments etc. LMD process can be applied for coating, repair and build near net shape geometries. One of the main problems of LMD applied in the coating or in the repair is the dealing with these different types of geometries, to achieve an adherent and homogeneous coating. The current calculation of toolpaths in LMD software is based on a mathematical algorithm that relies on subtractive processes such as machining. The main drawback of using this type of toolpaths is that in this case they do not take into account the overlap between adjacent machining toolpaths. While for machining this parameter is not relevant, in the LMD process, the overlap between two contiguous laser tracks is a critical point to have an adequate process with the required quality. Talens Systems has developed a new Software, Azala software is able to calculate these strategy toolpaths for advanced repairs and coatings in any type of geometry. Beside taking into account the overlapped between contiguous laser clads, the calculated toolpaths have integrated the main laser process in LMD (laser power, process speed, powder flow). The objective of this work is to validate the Azala software developed using a piece with complex geometry on a laboratory scale. The developed software brings the possibility to automate repair and coating, where the LMD process provides a value-added opportunity to reduce production costs due to the repair of value-added components.