Metallipinnoitus pinnoitusmenetelmien mahdollisuudet ainetta lisäävässä valmistuksessa

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1 Metallipinnoitus pinnoitusmenetelmien mahdollisuudet ainetta lisäävässä valmistuksessa J. Tuominen 1, J. Vihinen 2 Tampereen teknillinen yliopisto, Tampere Materiaaliopin laitos Kone- ja tuotantotekniikan laitos

2 Sisältö Yleistä pinnoitusmenetelmistä Laserpinnoitus: Jauhe Lanka Hybridimenetelmät Kaupalliset laitteet & sovellukset Materiaalit Komponenttien ominaisuudet Päällehitsaus kaarimenetelmillä CMT Terminen ruiskutus Kylmäruiskutus Edut, rajoitukset Yhteenveto Fusion bond Low dilution (single layer)

3 Classification of coating methods Energy from: High intensity light Combustion gases Kinetic energy Electric arc kj/m 2 : Moder Low Low High

4 Surface engineering Composite solution Sustainable Material efficient Global cladding/overlay welding markets expected to rise from 3.8 to 7.6 billion USD by 2015* * Abakan Inc. Global thermal spraying markets were 7.1 billion Eur in 2011* * The Linde Group, cladding Global market for AM will reach 3.5 billion USD by 2015* * Wohlers report Let there be light, Genesis 1:3

5 Principle of laser cladding Feedstock material (coating material in the form of powder or wire) is injected towards the base material and melted on the surface by the laser beam Part of the base material surface is melted, which provides good bonding, dense coatings and excellent surface properties

6 Laser cladding methods Powder and carrier gas Laser beam Powder and carrier gas Laser beam Shielding gas Clad layer Shielding gas Clad layer Substrate Substrate 2-step: preplaced powder 1-step: off-axis powder 1-step: coaxial powder 1-step: off-axis hot-wire (tandem) 1-step: coaxial cold-wire 1-step: coaxial hot-wire

7 Industrial laser cladding & applications ID cladding 1-step: coaxial powder On-site cladding Metallic and MMC coatings on metallic base materials Main benefits: Fusion bond Low dilution Low distortion Industrial cladding with 3-6kW lasers & powder feedstock: Low deposition rates (1-2 kg/h) Low material efficiency (~70%) New components / Remanufacturing (50/50)

8 High power laser cladding 2.1 mm Inconel 625: 15 kw, 1 m/min, 15 kg/h (500 mm3/s) New world record!!! jari.tuominen@tut.fi Laserpinnoitustekniikan Kunnossapitoforumpäivä 2015 Kokkola Tampere

9 Induction assisted laser cladding Without induction With induction Stellite 12 on M238 mould steel (646 x 230 x 196 mm 3 ) Fully closed-loop cladding process J. Tuominen, TUT Stellite 20 on AISI 1045 Chromalloy Gas Turbine Corp, USA F. Brückner, Fraunhofer IWS

10 Laser cladding cell

11 Process variables affecting the outcome

12 Kaupalliset laitteet (jauhe) HC-254 (Huffman) LENS 850-R (Optomec Inc.) EasyCLAD (BeAM) 1 5 kw fiber, disc or diode laser 5-axis gantry Several powder hoppers Working volume 900 x 1500 x 900 mm 3 Max component weight kg Controlled atmosphere (O 2 10ppm, H 2 O<50ppm) Closed-loop process control Software to create tool path from 3D CAD data (liikeradat) Powder is recycled Track width mm RPM s 557 (RPM DMD 505 (DM3D Inc.) Innovations Inc) Up to 50 mm 3 /s

13 Sovellusesimerkkejä Pituus 600 mm Airfoil (siipiprofiili) Inconel 625 NRC-CNRC Laskutelineen osa Ti6Al4V alloy AeroMet Corp.

14 Sovellusesimerkkejä Manufactured by DMD method Hip implant manufactured by LENS method Ti alloy Femoral component Manufactured by DMD method

15 Materiaalit Hardfacing alloys (Stellites, Tribaloy, Norem, Nanosteel, Self-fluxing alloys, Nistelle, Nucalloy) Superalloys (Inconel, Hastelloy, Monel, CMSX-4, high-cr NiCr) Tool steels (P20, M4, H13, CPM 10V) Stainless steels (316L, 254SMO, 420, 17-4 PH, duplex) Hadfield-steels (12-19%Mn, %C, 0-2.5%Cr ) Titanium alloys (Ti-6Al-4V, Ti6242, Ti grade 2) Copper alloys (CuAl, CuNi, CuSn) Aluminium alloys (AlSi5 (4043), AlSi10Mg, AlSi12, AlSi7Mg) Metal matrix composites (WC/W 2 C-NiCrBSi, TiC-Stellite, VC-tool steel, SiC-Al, synthetic diamonds) Solid lubricants (MoS 2, WS 2, CaF 2, graphite) Intermetallics (Cr 13 Ni 5 Si 2, MoSi 2, FeAl, NiTi) Gradient layers (FGM) (metal matrix composites, monolithes) Nanostructured and amorphous alloys, intelligent materials High entropy alloys

16 IN-625 microstructure Lähde: IMTI National Research Council Canada Laserpinnoitustekniikan päivä Kokkola Kunnossapitoforum 2015 Tampere

17 Mechanical properties (static) Complex thermal history (directional heat extraction, repeated melting & rapid solidification, repeated solid state transformations) Reduced grain size due to high solidification rates Directionally solidified structures Anisotropic mechanical properties Lähde: IMTI National Research Council Canada Laserpinnoitustekniikan päivä Kokkola Kunnossapitoforum 2015 Tampere

18 Ti6Al4V Laserpinnoitustekniikan päivä Kokkola Kunnossapitoforum 2015 Tampere

19 Corrosion resistance High cooling rates reduce partitioning Corrosion properties close to wrought alloys and better than cast structures Lähde: IMTI National Research Council Canada Laserpinnoitustekniikan päivä Kokkola Kunnossapitoforum 2015 Tampere

20 Dimensional accuracy & surface finish Lähde: IMTI National Research Council Canada Laserpinnoitustekniikan päivä Kokkola Kunnossapitoforum 2015 Tampere

21 Laser wire cladding & additive manufacturing University West, Trollhättan Fraunhofer IPT, Aachen Main benefits over powder: Material efficient (100%) Clean Possible to heat by resistive heating Chemically cleaner feedstock Less contamination during processing Cheaper than powder Tubular wires more challenging Laserpinnoitustekniikan päivä Kokkola Kunnossapitoforum 2015 Tampere

22 Coaxial wire cladding & additive manufacturing Precitec Mitsubishi Cavipro Fraunhofer IWS HighYAG/IWS

23 Coaxial hot-wire cladding & additive manufacturing Duplex: 3.5kW, 4m/min, 250A, 7V, 5kg/h (150 mm 3 /s) Main benefits: High process stability Less parameters in wire alignment Omni-directional Increased productivity Material efficient

24 Examples of laser wire manufactured parts

25 Laser + arc hybrid cladding & additive manufacturing Arc between two wires steel, 63 HRC steel Laser + MIG/MAG, single wire steel, 38 HRC, 2 kg/h Mild steel Twin wire 10kg/h Main benefits: Low dilution Low heat input Increased productivity Low power capacity laser source (<500W) Stabilization & guidance of electrical arc by laser More stable process

26 Kaupalliset laitteet (EB lanka) Sciaky Inc. Working space 5791 x 1219 x 1219 mm 3 Deposition rate 3 9 kg/h Titanium, Tantalum, Inconel, Stainless steels Closed loop process control

27 Cold metal transfer (CMT) cladding & additive manufacturing Advanced MIG High speed digital control Wire retracted at up to 140Hz Wire motion directly incorporated to electrical contol Max I = 280 A Solid wires up to Ø1.2mm Tubular wires up to Ø1.6mm Single wire, ~5kg/h Twin wire, ~10kg/h Main benefits: Low dilution Low heat input High productivity Material efficient Energy efficient (wall-plug, process) Power by aggregate On-site eligible ID cladding, Ø>100mm Low investments No optical elements Low safety precautions

28 Cold metal transfer (CMT) cladding & additive manufacturing Alloy 625 Ti6Al4V (Ø= mm) Ni-based Al alloys Bronzes Refuse incinerators and power stations Boiler walls and pipes (coal, waste, biofuel) ( C) Turbine rotors (hydropower) Ship propellers Mould repair Alloy 625 Valves

29 Cold metal transfer (CMT) additive manufacturing α-al primary dendrite (light) Al/Si eutectic (dark) 4.1 mm 11 µm 50 HV0.05 Transverse cross-section of AlSi5 build-up Al Ra 3.0µm 150 layers Si 40 mm3/s Hypoeutectic AlSi5 (4043) by robotguided CMT process 15 µm Elemental maps of Al and Si Laserpinnoitustekniikan Kunnossapitoforumpäivä 2015 Kokkola Tampere

30 Sovellusesimerkkejä Cranfield University Steel/bronze Cranfield University Pelton runners for hydropower stations Cranfield University Stiffened panel / Aluminium Cranfield University Cranfield University

31 Comparison of novel metal deposition techniques Characteristics High deposition rate Coaxial hot-wire LMD CMT LMD Laser power 15 kw 3.5 kw 0 kw Materials diversity Large (powders) Limited (wires) Limited (wires) Part dimensions No limitations No limitations No limitations Part complexity Limited Limited Limited Min. wall thickness ~10 mm 1 mm 3 mm Layer thickness mm mm 1 5 mm Deposition rates Up to 500 mm 3 /s Up to 150 mm 3 /s Up to 150 mm 3 /s Heat input kj/m kj/m kj/m Investments High Moderate Low Energy efficiency Low Moderate High Material efficiency ~80% ~100% ~100%

32 Ominaisuudet Suorakerrostus Jauhepeti Materiaalit laaja materiaalivalikoima jauhe, lanka Kappaleiden koko kappaleiden/suutinpään käsittelyjärjestelmä rajoittaa Kappaleiden monimutkaisuus Suorakerrostus vs. jauhepeti rajoittunut (materiaalvalikoima kasvaa nopeasti) prosessikammio rajoittaa rajoittunut lähes rajoittamaton Tarkkuus 0.1 mm 0.1 mm Tuotto 150 mm 3 /s 20 mm 3 /s Alusta 3D-pinta aihio tasainen pinta tasainen aihio Pinnankarheus R z µm µm Kerrosten paksuus mm mm

33 Terminen ruiskutus muodonantomenetelmänä

34 Additive manufacturing by cold spray 34

35 Ref. Peter Richter Jr, Advanced High Pressure Cold Spray Laserpinnoitustekniikan Kunnossapitoforumpäivä 2015 Innovative Technology Playground, North American Cold Spray Conference, Canada, 2014 Kokkola Tampere

36 Coaxially laser assisted cold spray COLA ( The European Union 7 th Framework Programme ): new, cost-effective laser-assisted cold-spray technique, for high-quality deposition and repair jari.tuominen@tut.fi Laserpinnoitustekniikan päivä Kokkola

37 Yhteenveto Suorakerrostukseen soveltuvia pinnoitusmenetelmiä: 1. Laserpinnoitus (jauhe, lanka) 2. Päällehitsaukseen soveltuvat kaarihitsausmenetelmät (kylmäkaari) 3. Terminen ruiskutus (kylmäruiskutus) 4. Hybridimenetelmät (laserkuumalanka, laser+kaari, laser+ruisku) Jauhepetiin nähden: Suurempi tuottavuus (isommat kappaleet) Alhaisempi resoluutio Alhaisempi mittatarkkuus Alhaisempi pinnanlaatu