Laser Direct Metal Deposition (DMD) at TWI

Trumpf DMD505 laser deposition system installed at TWI Yorkshire

Huffman HC205 laser deposition system

Thick DMD deposit

Thin DMD deposit

Section through tungsten carbide hard facing

DMD nozzle

Laser deposition for repair, build and rapid prototyping

TWI's laser direct metal deposition systems use lasers supplying beams which can be focused to a spot from 0.2mm to 2.5mm plus in diameter. This makes the process suitable for depositing both fine detail and bulk material alike.

The equipment housed at this unique facility, located at TWI's Yorkshire site, gives the company an outstanding range of capabilities, which are relevant to a range of applications.

Lasers are used because of their accuracy and low heat input, allowing fully dense, defect free deposits to be made. The process provides rapid, accurate placement of material at low heat input allowing the use of crack-sensitive alloys such as nickel-based alloys.

For more information, click here, or contact Dr Robert Scudamore.

Equipment

• Huffman 5-axis gantry system utilising a PRC laser
• Trumpf 5-axis gantry system
• 7kW IPG Yb-fibre laser and Kuka robot based high deposition rate cell
• Laser powder bed system - Q4 2007
• Selective laser melting system - MCP SLM 100 Selective laser melting system - MCP SLM 250

Capabilities

• Used for component repair, original part build, hybrid manufacture or material surfacing
• Closed loop feedback control capability regulates the deposit height
• Powder delivery head manipulated by 5-axis based systems to facilitate deposition in three dimensions
• Reactive metals deposited without need for protective atmosphere; atmospheric chamber available where necessary
• Wide range of metals can be deposited, including Inco625, Inco718, Waspaloy and titanium Ti-6Al-V4
• Methods of powder recycling lead to better process efficiency
• Deposition of metallic glasses and amorphous materials
• Microfocus X-ray facility for inspection of porosity and surface roughness
• Bespoke DMD CAM software for complex 3D shape generation
• Experience with functionally graded materials

Typical Applications:

• Build of medical implants
• Repair of mould tool surfaces
• Repair of high value parts such as aero engine components and military vehicles
• Tipping of turbine blades with protective coatings
• Surfacing of oil and gas drilling components

Further Information:

• Laser DMD Knowledge Summary
• TWI's Laser Processing Facilities and Expertise
• TWI's Laser Equipment
• Laser Process Cuts Repair Costs
• Nickel superalloys - their welding and deposition
• The effect of average powder particle size on deposition efficiency, deposit height and surface roughness in the direct metal laser deposition process
• Laser deposition of functionally graded material TWI Report 867/2007 Industrial Members Only