Laser Additive Manufacturing (LAM) has brought a paradigm shift to “feature based design and manufacturing” and is being considered as an integral part of fourth industrial revolution. LAM has paved the way for the fabrication of metallic components layer by layer with complex shapes and designs directly form 3D CAD model. A state of art architecture is developed and deployed for integration of LAM-PF-DED system yielding near-net-shaping and repairing of various engineering metallic components/ coatings. In the developed system, a commercially available multi-mode fibre laser (up to 2 kW) is used, a delivery fibre is used to deliver laser beam through refractive focusing optics and is integrated with indigenously developed compact co-axial nozzle coupled, twin powder feeder for powder feeding for laser additive manufacturing in a built envelope of 250 mm x 250 mm x 250 mm in controlled atmosphere conditions. The LAM built component ensures structural properties.

1. Highly efficient laser for prolonged operation
2. Multi-material laser additive manufacturing
3. Laser additive manufacturing in controlled atmosphere with competence to control moisture and oxygen below 25 ppm.
4. Online monitoring and control of atmospheric impurities.
5. Minimum changeover time.
6. Open architecture configuration for customize interfacing.
7. No restriction for selection of specific consumables.
8. Laser Additive Manufacturing of Complex Shape geometry.
9. High accuracy and surface finish.
10. Wide material range.

Laser Additive Manufacturing (LAM) has brought a paradigm shift to “feature based design and manufacturing” and is being considered as an integral part of fourth industrial revolution. LAM has paved the way for the fabrication of metallic components layer by layer with complex shapes and designs directly form 3D CAD model. A state of art architecture is developed and deployed for integration of LAM-PF-DED system yielding near-net-shaping and repairing of various engineering metallic components/ coatings. In the developed system, a commercially available multi-mode fibre laser (up to 2 kW) is used, a delivery fibre is used to deliver laser beam through refractive focusing optics and is integrated with indigenously developed compact co-axial nozzle coupled, twin powder feeder for powder feeding for laser additive manufacturing in a built envelope of 250 mm x 250 mm x 250 mm in controlled atmosphere conditions. The LAM built component ensures structural properties.

A solid model of the component to be fabricated is made either by 3D imaging system or by designer using computer aided design (CAD) software or by math data as an output of numerical analysis. The obtained model is sliced into thin layers along the vertical axis. The thin layers are converted into corresponding numerical controlled (NC) code and are sent to LAM-PF-DED station in G & M code format. LAM-PF-DED station employs a laser beam as a heat source to melt a thin layer on the surface of the substrate/deposited material and fed material to deposit a new layer as per shape and dimensions defined in NC code. A number of such layers deposited one over another results in three dimensional (3D) components directly from the solid model.

SPECIFICATION

1. Highly efficient laser for prolonged operation
2. Multi material laser additive manufacturing
3. Laser additive manufacturing in controlled atmosphere with competence to control moisture and oxygen below 25 ppm.
4. Online monitoring and control of atmospheric impurities
5. Minimum changeover time
6. Open architecture configuration for customize interfacing
7. No restriction for selection of specific consumables
8. Laser Additive Manufacturing of Complex Shape geometry
9. High accuracy and surface finish
10. Wide material range

LAM-PF-DED system provides the following salient advantages for the fabrication of metallic engineering components:

1. Eliminates many manufacturing steps, such as materials-machine planning, man-machine interaction, intermittent quality checks, assembly and related human errors etc.
2. Near net shaping of 3D components.
3. Repairing/rebuilding of worn-out parts.
4. Selective deposition with matching/graded chemistry using different materials.
5. Low distortions/ residual stresses.
6. Good metallurgical bonding at interface.
7. Overall short turn-around time.

The LAM-PF-DED system can be used for prototyping, product development, low volume manufacturing and repair of various metallic engineering components/ coatings.

FACILITIES REQUIRED

1. Floor Space (at least 100 sq m) required for integration and testing
2. Drilling & Fitting facility with general metrology instruments.
3. Electrical test and measurement equipment such as Multimeters, Clamp on Meters, Oscilloscope, Megger, General Kit etc.
4. Utilities like compressed air, cooling water and electrical power.

MANPOWER

Two graduate engineers (Mechanical and Electronics) having experience in working with machine automation/ robotics/ machine tool development, three ITI trained technicians (One electronics and two fitters) are sufficient to start production.