TECHNOGENIA and IREPA LASER: Pioneering Sustainable Laser Cladding Solutions

A collaboration between TECHNOGENIA and IREPA LASER to revolutionize laser cladding processes for sustainability.

Challenge

TECHNOGENIA sought to enhance the deposition of tungsten carbides on intricate 3D parts, aiming for a breakthrough in efficiency and sustainability.

The challenge consists in depositing Tungsten carbides by DED-p process on a complex 3D part in short time

Goals

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  • Process window set up Metallurgical feasibility
  • Define deposition strategy to deposit WC in each area
  • Manufacture a demonstration part 

Main contrains

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  • No materials in the insert locating
  • Single bead Width should be approx. 2,5 mm
  • Minimize the pre-processing time
  • Avoid metallurgical defects

Implemented Technology 

Wire Arc Additive Manufacturing (WAAM)

Wire Arc Additive Manufacturing (WAAM)

Service: Interoperability Validation of External Technology

Implementation Process:

A DED Digital Chain and an AM DED machine were deployed, leveraging advanced path planning and toolpath programming tailored to laser cladding.

Strategic development and simulations were conducted to facilitate collision-free operations, ensuring seamless integration into existing systems.

The process was organised as follows:

Step 1. Process window set up. Metallurgical feasibility on multiple layers

Step 2. Offline programming. Robot arm tool path and software implementation

Step 3. Demonstration part manufacturing

The drilling head was divided into 4 different zones. For each area, a specific deposition strategy was applied. The four toolpaths programs were merged in order to obtain the final deposition path. 

A machine simulation was performed to ensure there were no collision or path issues.

Results

Improvements in significantly improved wear resistance for drilling heads

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New benchmark for sustainable laser practices

Accelerating the time it takes to bring new products to market

The NI based alloy + Tungsten Carbides were successfully deposited on the drilling head

  • The path planning strategies defined allow most wear areas to be treated while ensuring good bead overlap
  • Tool path programming and machine simulation performed in less than 3 hours

Developer

Related Technologies:
Directed Enery Deposition (DED) Metal Additive Manufacturing (MAM)
Laser Metal Deposition (LMD)

Project info:

The use case is part of Technogenia’s involvement in the Horizon 2020 INTEGRADDE project, Grant Agreement noº 820776, aiming to innovate the field of Additive Manufacturing​​​​.