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Institute
Coaxial Laser wire Direct Energy Deposition (L-DED) promises a direction-independent buildup due to a centric supply of the welding material. To fabricate Functionally Graded Materials (FGMs), a processing head was designed that is capable of supplying two wire materials into the processing zone. This study investigates the direction dependency of welding seams produced by two 1.4718 metal wires with a diameter of 0.8 mm in a coaxial laser setup using three separately controllable single laser beams with a maximum combined laser power of 660 W. The welding wires are supplied simultaneously to the laser spot under an incidence angle of 3.5° to the middle axis of the processing head. The seam geometry is investigated using a confocal laserscanning-microscope. A comparison of the height, width and macroscopic seam geometry reveals the influence of the welding direction on the seam geometry and quality in Laser Double wire Direct Energy Deposition (LD-DED).
Tensegrity structures are structures in which elements stabilize each other by bearing compressive or tensile loads. They have a high potential for lightweight design. As structures with tensile loads, wires can be used that are connected to other structures using a laser bonding process. Investigations of bonding a mild steel wire with a diameter of 1 mm onto a flat substrate have been conducted using a coaxial deposition welding head. The influence of the parameters focus position, laser power, wire feed rate and bonding processing time has been investigated regarding the bonding quality. A process window for a stable process and a sufficient bond of wire and substrate was determined. The laser intensity and stickout length have a significant influence on the bonding. High intensities and stickout lengths lead to wire burn back and no bond with the substrate while wire backup occurred at low intensities and stickout lengths.
