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Using wire shaping techniques and holographic optics to optimise deposition characteristics in wire-based laser cladding

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journal contribution
posted on 26.01.2017 by Nick Goffin, Rebecca Higginson, John Tyrer
In laser cladding, the potential benefits of wire feeding are considerable. Typical problems with the use of powder, such as gas entrapment, sub-100% material density and low deposition rate are all avoided with the use of wire. However, the use of a powder-based source material is the industry standard, with wire-based deposition generally regarded as an academic curiosity. This is because, although wire-based methods have been shown to be capable of superior quality results, the wire-based process is more difficult to control. In this work, the potential for wire shaping techniques, combined with existing holographic optical element knowledge, is investigated in order to further improve the processing characteristics. Experiments with pre-placed wire showed the ability of shaped wire to provide uniformity of wire melting compared with standard round wire, giving reduced power density requirements and superior control of clad track dilution. When feeding with flat wire, the resulting clad tracks showed a greater level of quality consistency and became less sensitive to alterations in processing conditions. In addition, a 22% increase in deposition rate was achieved. Stacking of multiple layers demonstrated the ability to create fully dense, three-dimensional structures, with directional metallurgical grain growth and uniform chemical structure.

Funding

This research has been funded by the Engineering and Physical Sciences Research Council (EPSRC) in the UK, via a research student scholarship grant, and carried out as part of the activities of the Optical Engineering Research Group of Loughborough University.

History

School

  • Aeronautical, Automotive, Chemical and Materials Engineering

Department

  • Materials

Published in

Proceedings of the Royal Society of London. Series A, Mathematical and physical sciences

Citation

GOFFIN, N.J., HIGGINSON, R.L. and TYRER, J.R., 2017. Using wire shaping techniques and holographic optics to optimise deposition characteristics in wire-based laser cladding. Proceedings of the Royal Society of London. Series A, Mathematical and Physical Sciences, 472, article no. 200160603

Publisher

The Royal Society (© The Authors)

Version

VoR (Version of Record)

Publisher statement

This work is made available according to the conditions of the Creative Commons Attribution 4.0 International (CC BY 4.0) licence. Full details of this licence are available at: http://creativecommons.org/licenses/ by/4.0/

Acceptance date

25/11/2016

Publication date

2017

ISSN

0080-4630

Language

en

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