Generative manufacturing and repair of metal parts through direct laser deposition using wire material

Abstract

In the field of Laser Additive Manufacturing, modern wire-based laser deposition techniques offer advantageous solutions for combining the high quality level of layer-by-layer fabrication of high value parts with the industry’s economical requirements regarding productivity and energy efficiency. A newly developed coaxial wire head allows for omni-directional welding operation and, thus, the use of wire even for complex surface claddings as well as the generation of three-dimensional structures. Currently, several metallic alloys as steel, titanium, aluminium, and nickel are available for the generation of defect-free structures. Even cored wires containing carbide hardmetals can be used for the production of extra wear-resistant parts. Simultaneous heating of the wire using efficient electric energy increases significantly the deposition rate and energy efficiency. Examples of application are light-weight automotive parts, turbine blades of Nickel super alloys, and complex inserts of injection moulds.