研究目的
Investigating the development of a methodology for measuring and correcting height deviations in the laser metal wire deposition (LMWD) process to improve process robustness and part quality.
研究成果
The developed methodology proved effective in correcting local intra-layer defects and maintaining part integrity. The combination of mean layer height error corrections and local corrections based on scanning speed variation resulted in a reliable method for improving the LMWD process.
研究不足
The precision of the robot's movement and the need for calibration and communication between the manufacturing environment and scanner may affect the applicability of the methodology to different machine configurations and measurement systems.
1:Experimental Design and Method Selection:
The methodology involved measuring the part layer by layer using a 3D scanner based on structured laser light and applying height corrections by recalculating deposition trajectories.
2:Sample Selection and Data Sources:
The study used 316LSi stainless steel filler material in the form of
3:8 mm diameter wire. List of Experimental Equipment and Materials:
The LMWD cell included a 4 kW Ytterbium Laser System YLS4000, an IRB4400 robot, a wire feeder, a COAXwire deposition head, and a Phoxi 3D structured light scanner.
4:Experimental Procedures and Operational Workflow:
The process involved stopping after each layer deposition, scanning the upper surface, and calculating trajectories for the next layer based on the scanned height profile.
5:Data Analysis Methods:
The height deviation was divided into mean and intra-layer errors, with corrections applied by varying the scanning speed.
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Ytterbium Laser System
YLS4000
IPG Photonics
Processing laser for the LMWD process
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Vision Camera
Genie Nano C1940 CMOS
Teledyne DALSA
Monitoring wire feeding
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Robot
IRB4400
ABB
Deposition movement
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Wire Feeder
DINSE G.m.b.H.
Introducing filler material
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Deposition Head
COAXwire
Fraunhofer IWS
Divides the main laser beam into three beams and focuses them again on the working plane
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Structured Light Scanner
Phoxi 3D
Photoneo
3D measurement of the part
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