Product Code: ICA13_1202

Laser-Based Generation of Precise Functional Structures and Components
Frank Brueckner, Fraunhofer IWS; Dresden Germany
Mirko Riede, Fraunhofer Iws Dresden; Dresden Germany
Thomas Finaske, Fraunhofer Iws Dresden; Dresden Germany
Steffen Nowotny, Fraunhofer Iws Dresden; Dresden Germany
Christoph Leyens, Fraunhofer Iws Dresden / Technische Universitaet Dresden; Dresden Germany
Eckhard Beyer, Fraunhofer Iws Dresden / Technische Universitaet Dresden; Dresden Germany
Presented at ICALEO 2013

Functionalization of surfaces as well as the precise generation of metallic components are increasingly required in specific applications, especially in aviation, medical technology and micro tooling industry. The utilization of such parts is not only combined with beneficial (material) properties including, for example, almost no porosity or cracking even on complex shaped parts, but also high flexibility and high robustness in processing. Some applications even require rapid adaptations of the generated geometry, e. g. to satisfy personal requirements of patients in the area of medical parts.
By means of strongly reduced melt pool dimensions the generation of miniaturized structures and components can be realized up to a detail resolution within the double-digit micrometer range. This can be reached by the use of suitable laser sources (e. g. fiber and disc lasers). It also requires the implementation of precise powder nozzle systems, modified process equipment and new coating strategies supported by CAD/CAM interfaces. High precision laser cladding yields small heat affected zones and improved near-net shape contours. The interaction of complementary equipment permits a good reproducibility, but typically a rather low deposition rate.
The comparison with high productive laser cladding which is characterized by deposition rates up to 15 kg/h shows the huge variability of this process. Hence, there is almost an order of magnitude of three between the smallest and the largest laser cladded weld bead track.

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