Deposition 3D Scan
The Deposition 3D Scan project innovatively utilizes an image processing-based algorithm for precise 3D profiling of laser additive manufacturing-deposited layers. Achieving remarkable accuracy, with 96% in width and 98% in height detection, surpassing ISO standards, this non-destructive method outpaces conventional approaches in both accuracy and simplicity. The incorporation of a single camera enhances practicality. This advanced solution offers a streamlined and accurate means of assessing deposited tracks, marking a significant stride in non-destructive quality control for additive manufacturing.
Repairing a Titanium Impeller
Innovative laser additive manufacturing technique was employed to successfully repair a titanium impeller, addressing challenges related to material integrity and complex geometry. The utilization of a positive-pressure chamber ensured proper gas shielding, resulting in multiple shiny silver layers. The added layers exhibited optimal hardness, matching that of the base metal since the laser additive manufacturing created a deposited layer with minimal Heat Affected Zone (HAZ) and a distinctive Widmanstätten microstructure in the fusion zone. This project showcases advancements in precision and efficiency for titanium impeller repairing.
Titanium LMP Shielding Chamber
The susceptibility of titanium to oxidization poses a formidable challenge during laser materials processing, especially at temperatures exceeding 450°C. To counteract oxygen absorption, an effective shielding mechanism is imperative. Numerous shielding chambers have been explored, each with its shortcomings. This project introduces an innovative solution—a positive-pressure chamber, adept at rectifying previous design flaws and ensuring uninterrupted shielding during laser materials processing of titanium alloys, illustrated in Figure 1. The discussion culminates in the examination of an additively manufactured titanium sample crafted within this enhanced chamber, showcasing the practical implications of our shielding solution.
Aluminum to Copper Dissimilar Laser Joining
Dissimilar joints especially aluminum (Al) to copper (Cu) have been drawn enormous attention in recent years. Challenges of joining aluminum to copper could be (1) high thermal conductivity and high reflectivity of these metals and (2) formation of Intermetallic Components (IMCs). To overcome these shortcomings, a method is presented for dissimilar joining aluminum to copper with stainless steel 316L interlayer. The method is included laser welding and laser material deposition processes for creating bimetal and attaching it to the base metal. It has been seen this resulted joint was deeper and wider than previous studies.
Laser Welding Seam Tracking
The primary hurdle in programming of laser welding’s motion systems lies in the alignment of laser beam with the seams to achieve a high-quality weld. Traditionally, achieving such weld joints necessitated the programmer to manually set numerous points along the seam—a time consuming process. In response to this challenge, our project introduces a real-time seam tracking system. This system is adept at sensing and generating the optimal welding path in real-time, concurrently guiding the robotic system accordingly. A camera captures online images, and a processing algorithm analyzes these images to accurately indicate the welding path.
Manufacturing of Rotary Cutter
At the Metalaser Laboratory, we developed a process for manufacturing a rotary cutter for the pelletizing process in petrochemical companies. Rotary cutters are mainly subjected to wear and cyclic fatigues due to harsh and wear-full environments in which they are utilized. Using laser directed energy deposition (L-DED), a wear-resistance material deposited on the base metal. This process decreased the overall cost following lower material consumption and enhanced the part’s life cycle intensively.
Aero-turbine Blade Repairing
In Metalaser Laboratory, we have pioneered a restoration process for damaged High-Pressure Turbine (HPT) blades in aero gas turbine engines. Leveraging Laser Directed Energy Deposition (L-DED), our method involves using a laser beam to forge a robust metallurgical bond between the machined surface of the damaged part and filler metal, adhering to on-the-shelf and new blade specifications. The process on the blades underwent rigorous testing through Finite Element Method (FEM), and the resulted microstructure of the added layers was investigated by Optical Microscopy (OM).