Recent Advances in Laser Deposition for Repair and ...

Recent Advances in Laser Deposition for Repair and Additive ManufacturingTed Reutzel, Rich Martukanitz, Shawn Kelly, Todd Palmer, Ken Meinert, Jay Tressler, Drew Nissly, Sean Krieger

Applied Research Laboratory, Pennsylvania State Universitypp y, y y

Presented at:The 4th Laser Additive Manufacturing Workshop (LAM 2012)Houston, TexasFebruary 29, 2012

Distribution Statement A: Approved for Public Release, Distribution Unlimited

Funded by the Office of Naval Research’s ManTech Program through the y g gInstitute for Manufacturing and Sustainment Technology,Contract No. N00024-02-D6604, Delivery Order No. 0019.

Laser Processing Division

ARLPenn State

Presentation OutlinePresentation OutlinePresentation OutlinePresentation Outline

Introduction

Laser deposition for: Repair Direct Digital Manufacturing

Center for Innovative Material Processing through Direct Digital Deposition (CIMP-3D)

Summary

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LaserLaser--Based Deposition ProcessesBased Deposition ProcessesLaserLaser--Based Deposition ProcessesBased Deposition Processes

Laser-BasedDeposition Processes

Modifying aProducing a Producing aModifying aSurface

Producing aUnique Material

Producing aComponent

New Part Repair orRestoration

BulkDeposition

SurfaceDeposition

Deposition

2D 3D

CladdingSurfaceAlloying Full

pon Substrate

SelectiveMicro Repair

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Densification Sintering

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LaserLaser--Based RepairBased RepairCurrent TrendsCurrent Trends

LaserLaser--Based RepairBased RepairCurrent TrendsCurrent Trends

Portable laser based repair of corrosion and wear resistant surfaces Portable laser based repair of corrosion and wear resistant surfaces Removal of components is costly, difficult, and/or impossible, which requires in-

situ repair and minimal distortion of the component

Vertical Launch System Tubes

Sea Water Valves

R t ti f hi h l t Restoration of high value components Existing repair techniques can cause unacceptable distortion

Large Machinery Shafts

Repair of aerospace components requires high quality

Titanium aerospace component

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ARLPenn State

Repair of theRepair of theVertical Launch SystemVertical Launch System

Repair of theRepair of theVertical Launch SystemVertical Launch System

Pitting corrosion of undersea systems can result in costly repair Material comprised of Inconel 625 on HY-80 steel

A multi-function, portable laser deposition d t h b d l dprocess and system has been developed

for portable repair System provides automated machining and laser

deposition using a 4 kW fiber laser and wire feed stock

Courtesy NUWC Keyport

p g

System implemented and in use at Pearl Harbor Naval Shipyard in December 2010

Development Team: Pearl Harbor Naval Shipyard Naval Undersea Warfare Center - Keyport

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Naval Undersea Warfare Center Keyport ARL Penn State Naval Sea Systems Command

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Repair ofRepair ofSeawater ValvesSeawater Valves


Portable processing is being extended to other undersea systems: y Large valves representing multiple materials

Must utilize existing 4 kW ytterbium fiber laser and solid wire feed stocklaser and solid wire feed stock

Must be capable of out-of-position deposition for internal and external Courtesy PHNSY psurfaces Minimum internal diameter of approximately 150 mm

D l t T

A AD

B

D

Courtesy PHNSY

Development Team: Pearl Harbor Naval Shipyard ARL Penn State Naval Undersea Warfare Center - Keyport

C

EE

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Naval Sea Systems CommandCu-NiNi-Cu Inconel 625

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Project Objective:Implement an alternative repair technology and/or

f t l

AMET, Inc.

process for seawater valves.

Key Technology Drivers:y gy• Ship-deployable

• Modular and portable• Flexible manipulation systems• Out-of-position weld clad repair• Multiple materials• Wire-based, deep-bore laser clad or GTAW

This effort has developed and is transitioning these technologies

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is transitioning these technologies.

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Shield Gas Supply

Water Cooled

Focus Lens

Set Screw to Mirror

Cover Lens

Adjust Flow

Gas Diffuser Ring

Cover Lens Tray

4 inch ID

8

g4 inch ID

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• Developed detailed Technical Specification in collaboration with Navy shipyards.

• Conducted Preliminary and Final Design• Conducted Preliminary and Final Design Reviews with Navy engineers and technicians.

1. Rotation Axis Drive/Guidance System2. X-Axis Linear Slide (XVC)3. Manual Cross Axis4. Z-Axis Linear Slide (XVC)5 Manual Torch Extension Clamp

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5. Manual Torch Extension Clamp6. Motorized Wire Nozzle Positioner7. Fixture Mount Plates8. Intertest Vision System

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Cases to be used for all system components. GTAW power supply and wire feeder.

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Downhand set up. Out-of-position set up.

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Integrated system was demonstrated with laser cladding in October 2011laser cladding in October 2011

Cost savings anticipated to be $17M over 10 years if implemented at all four hi dshipyards Reduced repair times and cost for individual repairs. Doubling time required between repairs

Navy certification agencies have been engaged throughout the development effort

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Out-Of-Position Laser Cladding Evaluations

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100 ipm WFS, no preheat, Ar‐5%H2 shield gas

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Repair of Repair of Large Machinery ShaftsLarge Machinery Shafts


Continual wear of large machinery shafts requires dimensional restorationq

Requires repair without damaging asset minimal metallurgical modification low thermal distortion

Restoration process requires thick deposit at high deposition rates and minimal distortiondeposition rates and minimal distortion relatively high laser power

scanned beam

powder feed stock powder feed stock

Initial evaluations directly compared laser deposition with traditional cladding processes

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deposition with traditional cladding processes laser deposition achieved an increase in deposition rate of

approximately 70% with a reduction in heat input of 50%

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Design for shipyard utilizationDesign for shipyard utilization

Must operate safely in conventional production environmentproduction environment

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Laser Fiber Coupler

Galvanometer

IR Temperature Sensor

Inter-pass Camera

Process Camera

Light

Cover Slides

Cooling Lines for Powder Feeder

Light

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Powder Feeder – Adjustable in X, Z and Rotational Directions

Shield Gas Nozzle

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)

1.60

1.654 kW 6 kW9 kW12 kW

- 40 mm from focus

Dia

met

er (m

m)

1.50

1.55

at focus0 1 2 3 4 5 6

D

1.40

1.45

Time (min)

+ 40 mm from focus

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Mechanical Properties of Laser DepositedMechanical Properties of Laser DepositedTiTi--6Al6Al--4V for Repair Applications4V for Repair Applications

Mechanical Properties of Laser DepositedMechanical Properties of Laser DepositedTiTi--6Al6Al--4V for Repair Applications4V for Repair Applications

Goal: Evaluate samples produced

S.M. Kelly (ARL Penn State)

by several laser-deposition systems against a common testing protocol.

Application: Thin-wall Ti-6Al-4V repair, required to be less than 2 mm thick and less than 2 mm wide.

Approach: Coupon testing of two powder-based laser repair processes was conducted to assess mechanical

Tension Testing: YS and UTS exceed AMS 4911 minimums; elongation

properties for a Ti-6Al-4V repair application.

gbelow.

Bending fatigue: Lifetimes for repaired coupons lower than baseline

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AMS 4911 plate samples.

ARLPenn State Direct Digital ManufactureDirect Digital ManufactureDirect Digital ManufactureDirect Digital Manufacture

Enabling technologies for Direct Digital Manufacturing Enabling technologies for Direct Digital Manufacturing Impact of using recycled powder. Use of:

d sensors and simulations

for prediction of material properties.

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Mechanical Properties of Laser Deposited TiMechanical Properties of Laser Deposited Ti--6Al6Al--4V Using Recycled Powder4V Using Recycled Powder


S.M. Kelly, F. Lia, K.C. Meinert, M.J. Policelli (ARL Penn State)P. D. Prichard, B. Sargent (Kennametal, Innovation Ventures Group)

Objective: Compare mechanical properties of virgin and recycled PREP powder.Feedstock concerns ith DDM Feedstock concerns with DDM technology implementers: Raw costs dictate what makes

economic sense Quality Availability

PREP powders have been the d f d d f DDM

Compare laser deposits produced from virgin and recycled PREPdefacto standard for DDM.

Powder DDM processes are not 100% efficient.Can PREP powder overspray be

from virgin and recycled PREP powder in the As-Deposited and HIP’ed and Heat Treated (HT) Condition

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Can PREP powder overspray be recycled?

Tensile, Fatigue, Chemistry, Microstructure Comparison.

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ChemistryB th PREP d PREP R t 4999 Both PREP and PREP-R meet 4999 specs:

Oxygen Levels (<2000 ppm): PREP: 1510 ppm O2 PREP-R: 1470 ppm O2

Tensile and Yield Strength Both PREP and PREP-R meet AMS 4999

YS & UTS specs for z-direction. No statistical difference in PREP and PREP R No statistical difference in PREP and PREP-R

tensile strength properties. Both As-Deposited and Heated Treated (HT)

samples meet AMS 4999. As-Deposited samples exhibit higher strengthAs Deposited samples exhibit higher strength

than HT samples due to finer lath.

Ductility HT exceeds AMS 4911 plate ductility.

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HT exceeds AMS 4911 plate ductility. As-Deposited exceeds AMS 4999 ductility. As-Deposited samples exhibit lower ductility than

HT samples due to finer lath.

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Failed in Grip

Recycling powder makes no difference in processing, chemistry, microstructure, tensile strength or fatigue life after HIP and heat treatment.

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Recycling powder makes a slight difference in ductility for As-Depositedsamples.

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Collaboration on Navy DDM SBIR: Collaboration on Navy DDM SBIR: MultiMulti--Sensor/ModelSensor/Model--Based Controls Based Controls

for Additive Manufacturingfor Additive Manufacturing

Collaboration on Navy DDM SBIR: Collaboration on Navy DDM SBIR: MultiMulti--Sensor/ModelSensor/Model--Based Controls Based Controls

for Additive Manufacturingfor Additive Manufacturingfor Additive Manufacturingfor Additive Manufacturingfor Additive Manufacturingfor Additive Manufacturing

Process Validated Thermal History Microstructure ModelMelt Pool Thermal Sensor

J. Craig, T. Wakeman (Stratonics), S.M. Kelly (ARL Penn State)

Process (ARL Penn State) (ARL Penn State)(Stratonics)

High Dynamic Range Thermal Sensor

(Stratonics)

St t i d ARL P St t h t d N SBIR C tl t i• Stratonics and ARL Penn State have teamed on a Navy SBIR. Currently entering Phase II.

• Objective: Use multiple thermal sensors to predict (and ultimately control) defects and microstructure in DDM of Ti-6Al-4V.St t i th l id l ti f t t t f

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• Stratonics thermal sensors provide real-time surface temperature measurements of the melt pool and bulk temperature.

• ARL Penn State provides experimental support, process understanding, and microstructure modeling.

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Center for Innovative Material ProcessingCenter for Innovative Material Processingthrough Direct Digital Depositionthrough Direct Digital Deposition

Center for Innovative Material ProcessingCenter for Innovative Material Processingthrough Direct Digital Depositionthrough Direct Digital Deposition

DARPA’s Open Manufacturing Initiative

is establishing a

Manufacturing Demonstration FacilityManufacturing Demonstration Facility

through the

Center for Innovative Material Processing through Direct Digital Deposition (CIMP-3D)

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g p ( )

ARLPenn State

Center for Innovative Material Processing Center for Innovative Material Processing through Direct Digital Depositionthrough Direct Digital Deposition

Center for Innovative Material Processing Center for Innovative Material Processing through Direct Digital Depositionthrough Direct Digital Deposition

Goal:Establish the Center for Innovative Material Processing through Direct Di it l D iti (CIMP 3D) ld l f ilit f d l iDigital Deposition (CIMP-3D) as a world-class facility for developing and implementing DDM technology for critical components.

Mission:• advance enabling technologies required to successfullyadvance enabling technologies required to successfully

implement DDM technology for critical components,• provide technical assistance to industry through selection,

demonstration, and validation of DDM technology as an “honest broker”, and,

• promote the spread of DDM technology through training, education and dissemination of information.

Rationale:DDM technology is viewed as a means of significantly increasing national competitiveness in manufacturing and builds upon the U.S. strength in computer software and digital technology. Broad implementation of DDM technology within the U.S. will enable

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an extreme product flexibility while driving new paradigms in design, materials, and manufacturing.

Courtesy of Sciaky

ARLPenn State

Center for Innovative Metallic Processing Center for Innovative Metallic Processing through Direct Digital Depositionthrough Direct Digital Deposition


CIMP-3D is operated by the Applied Research Laboratory at Penn State and Sciaky and will include an extensive network of Center AssociatesAssociates.

Three direct digital manufacturing systems are being installed to provide state-of-the-art capabilities for producing net or near-net shape metallic components:s ape e a c co po e s

• Optomec laser-based, near-net, deposition system for moderate scale builds

• Sciaky electron beam-based, near-net, deposition system capable of large scale buildsg

• Powder bed, scanned laser-based system capable of high feature definition for small scale builds

The DDM system capabilities will be augmented by the vast f th L P i D t t ith 25resources of the Laser Processing Department with over 25 years

of experience in laser-based material deposition technologies

CIMP-3D will be housed in a new laboratory that will provide approximately 5,000 square feet for design and DDM development

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approximately 5,000 square feet for design and DDM development

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The CIMP-3D Shared Network will enable collaboration of Associates, as well as ,providing secure digital transfer of information and data for design, manufacturing demonstrations, and process verification

The network will also serve as link for utilizing advanced design, analysis, and simulation capabilities:

Design for DDM Module Design for DDM Module Process Planning Module Thermal Simulation Module Microstructural Development Module Phase Prediction Module

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ARLPenn State SummarySummarySummarySummary

ARL Penn State has a rich history of developing and applying laser-based deposition technology1pp y g p gy

Our sponsors are interested in the: Development and implementation of laser

d iti fdeposition for: portable repair processes, restoration of high value components, and

Development of enabling technologies for direct p g gdigital manufacture.

The future of laser deposition is being driven by technology that enables new applications.

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1 Archambeault, J. et al, Scientific and Technological Landscape of Laser Cladding: A Bibliographic Analysis of Patents and Publications, ICALEO 2005.

ARLPenn State Questions?Questions?Questions?Questions?

Th k fThank you for your interest.

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ARLPenn State The FutureThe FutureThe FutureThe Future

Factors that will encourage wider adoption of laser deposition technology:p gy Increased quality of starting material

narrower particle size distributions availability of special compositions availability of special compositions standard for powders used in laser deposition processes

Development of application guidelines and certification protocolsprotocols

Application of enabling technologies: Increased use of simulation techniques for process Increased use of simulation techniques for process,

microstructure, and functional control Exploitation of advanced materials and properties

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Repair of Repair of Seawater ValvesSeawater Valves

Repair of Repair of Seawater ValvesSeawater Valves

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Demonstration at PHNSY:We’ve been working with PHNSY throughout the effort:

• Participate in Final Design Review for Man-Portable Valve Repair System

• Provided Feedback on Mock-Valve• Provided Feedback on Laser Safetyy• Provided Feedback on Implementation Details• Provided Feedback on Weld Clad Test Results• Provided Wrought CuNi Plate for Additional Tests

A AD

C

B

EE

D

A C

BD

E E

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Interchangeable mounting plates simulate attachment surfaces for the various repairs.

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Specialized processing system designed to maximize deposition rate while also providing high process consistency: Reflective optical components Galvanometer-driven scanning beam Powder feed nozzle designed to eliminate clogging and Powder feed nozzle designed to eliminate clogging and

inconsistent powder flow Integrated sensors for process monitoring

Light-tight enclosure provides safe workingLight tight enclosure provides safe working environment within repair facility

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Shaft Seal Ring-Enclosure Connection

Enclosure box ends fit inside grove gin the ring. Tongue and groove prevents light from escaping.

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p g

ARLPenn State



Powder feed nozzles for pre-placed powder laser cladding are susceptible to clogging and inconsistent powder flow.To overcome this issue, a new powder feed nozzle has been designed and fabricated at ARL Penn State.

• Water cooling inlet/outlet

• Powder inlet

• Removable Base PlateRemovable Base Plate• Powder outlet protected

from metal spatter

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ARLPenn State

Repair ofRepair ofVibration Reducer CellsVibration Reducer Cells


Reducer cells are produced by forging a steel alloy, similar to AISI 1045 (Fe-0.43C-0.75Mn-0.22Si-0.04 P 0 05S )Pmax-0.05Smax) difficult to repair due to thermal distortion and

hydrogen assisted cracking

However repairing these components can achieve

Courtesy Edison Welding Institute

However, repairing these components can achieve significant cost saving and reduce delivery times initial evaluation by Edison Welding Institute

indicated that GTAW with a cobalt-based alloy f

Zone 2Depends Upon Welding

Zone 3Con

tent

(%)

Graville Diagram for Sensitivity to HACcould be utilized for repair but dimensional issues

Program initiated to develop repair process using Stellite 6 alloy powder:

Zone 1Safe Under Most Conditions

Conditions Zone 3High Under All Welding

Conditions

Car

bon

C Stellite 6 alloy powder: determine preheat and post-process thermal

processing requirements identify system requirements

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Carbon Equivalent

CE = %C + %Mn/6 + %Ni/15 + %Cr/5 + %Mo/4 + %V/5

CE1045 = 0.45 + 0.75/6 = 0.58

verify process may be qualified per NAVSEA transition process to the NUWC Keyport

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The deep bore deposition head has been modified to provide powder delivery

Process parameters have been established based on sub-scale specimens: laser power of 3 kW and 0.5 m/min. travel speed

produces good deposition quality laser power of 3 kW and 0.5 m/min. travel speed

produces good deposition quality preheating at 200oC results in adequate deposition

hardness, an acceptable near-HAZ microstructure, and minimal residual stress

Deposition cell currently being integrated for full scale evaluations that will include:full-scale evaluations that will include: pre and post-process dimensional measurements and

metallurgical analysis of reducer cells metallurgical analysis of deposit and substrate HAZ

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pre-qualification testing

ARLPenn State

Collaboration on Navy DDM SBIR’s:Collaboration on Navy DDM SBIR’s:(1)Controlled Thermal Processing of DDM Components(1)Controlled Thermal Processing of DDM Components

(2)Rapid Part Qualification Methodology of (2)Rapid Part Qualification Methodology of Aircraft Metallic Components using DDMAircraft Metallic Components using DDM

Collaboration on Navy DDM SBIR’s:Collaboration on Navy DDM SBIR’s:(1)Controlled Thermal Processing of DDM Components(1)Controlled Thermal Processing of DDM Components

(2)Rapid Part Qualification Methodology of (2)Rapid Part Qualification Methodology of Aircraft Metallic Components using DDMAircraft Metallic Components using DDMAircraft Metallic Components using DDMAircraft Metallic Components using DDMAircraft Metallic Components using DDMAircraft Metallic Components using DDM

Anil Chaudhary (Applied Optimization), S. Babu (Ohio State), S.M. Kelly (ARL Penn State)

• Applied Optimization and ARL Penn State have teamed on two successful Navy SBIR’sNavy SBIR s.– Controlled Thermal Processing is beginning Phase II execution.– Rapid Part Qualification is awaiting Phase II award.

• Applied Optimization:• Applied Optimization:– Developed robust thermomechanical models for DDM– Developed process control simulation tools for DDM.

• ARL Penn State has supported the AO efforts with experimental support of

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• ARL Penn State has supported the AO efforts with experimental support of both programs.

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The Laser Processing Division of ARL Penn State has been actively involved in the development and CIMP-3Dimplementation of laser-based deposition technology for over 25 years

Laser processing for repair of highly engineered

Center for Innovative Metal ProcessingThrough

Direct Digital Deposition

A DARPAManufacturing Demonstration Facility

and Laser processing for repair of highly engineered components will continue to increase based on: its ability to provide a durable repair, offering a myriad of material options, while

anda national resource for the advancement,

implementation, and dissemination ofdirect digital manufacturing technology

minimizing metallurgical damage and thermal distortion to the substrate

Laser repair technology is being exploited to provide p gy g p preal world solutions to the U.S. Navy, DoD, and industry

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ARLPenn State

Repair of Repair of Shaft Seals and Mating RingsShaft Seals and Mating Rings

Repair of Repair of Shaft Seals and Mating RingsShaft Seals and Mating Rings

Shaft seals and mating rings can only be refurbished a limited number of times after which they are scrapped, leading to high costs for replacement and critical shortages in

LENS System at ARL Penn State

leading to high costs for replacement and critical shortages in the supply system

Laser based deposition processes are capable of depositing small amounts of material with minimal distortion to the overall part geometryoverall part geometry five year cost savings estimated at $18.2M

Currently developing repair process using Inconel 625: evaluate and develop powder-fed and wire-fed laser-e a uate a d de e op po de ed a d e ed ase

based deposition processes perform testing and material characterization to

determine suitability of process and material for repair develop qualification test plans for the selected laser

LENS System at NUWC Keyport

develop qualification test plans for the selected laser deposition process and obtain NAVSEA qualification

transition process to the NUWC Keyport

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ARLPenn State Laser-Based Deposition TechnologyLaser-Based Deposition Technology

1990 1995 2000 2005 2010

Laser Deposition of Tooling Material at Alvord Polk Corp.

In-Situ Processing

Martensitic SS – TiC

Laser Repair of

Laser Deposition of Aluminum Alloy at the NUWC-Keyport

Improved Fundamental ne

Multi-Deposit ofFe48Cr15Mo14Y2C15B6

Marine Components(NUWC-Keyport andPuget Sound NSY)

Laser Deposition forCommercialApplications

Laser-Based Deposition ofTooling Grade Material

(Alvord Polk Corp.)

pUnderstandingof Processes C

ryst

allin

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Applications(Caterpillar Corp. andBonney Forge Corp.) Laser Free Forming Under

DARPA Support(Aeromet Corp.)

Advanced CoatingMaterials

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A AD

C

B

D

EE

AB

C

D

E E

Interchangeable mounting plates simulate attachment surfaces for the various repairs.

Total Weight ~ 400 lbs

150 lbs

44Interchangeable ASW MSW bolt pattern plates

60 lbs

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