There is a growing interest in building metal structures using a layer by layer additive approach, for both component build and component repair. A technique using a high power diode laser with wire feed has been developed to achieve high deposition rate builds in Titanium alloys. The aim of this paper is to show the characteristics of the deposited materials and the interactions between features of the deposit and process parameters associated with this technique.
A 2.5 kW high power diode laser has been used to deposit Ti-6Al-4V and Ti-6Al-2Sn-4Zr-2Mo wires to successfully form single tracks and multi-layers deposits. The effect of varying laser power, process (table) feed rate and wire feed rate have been investigated. The resulting layers were studied and characterised using optical microscopy. Preliminary results indicated that extremely good and clean deposited surfaces and profiles were produced which was free from porosity and well bonded to the base substrate. Additionally, excellent deposition rates were achieved with low dilution.
Results from this early work have been promising. The direct metal deposition with high power diode laser and wires is an effective process for large area deposition and high quality deposits can be achieved.