TECHNOGENIA AND IREPA LASER: PIONERRING SUSTAINABLE LASER CLADDING SOLUTIONS
Use case in a Nutshell
Technogenia (early adopter), seeking to efficiently deposit tungsten carbides on complex 3D-drilling-head components, teamed up with IREPA Laser (tech developer) under the INTEGRADDE programme. The goal was to develop a high-speed, sustainable laser cladding process that minimized defects and pre-processing efforts .
About the collaboration partners
Lead integrator driving innovation in additive manufacturing via DED-based solutions .
Specialist in laser cladding and AM/DED machine simulations, supplying the machinery, path planning, and implementation tools .
Description of the Collaboration
Problem Addressed
Technogenia needed to deposit tungsten carbide coatings on intricate 3D parts quickly while maintaining high sustainability and avoiding metallurgical defects.
The challenge consists in depositing Tungsten carbides by DED-p process on a complex 3D part in short time
The main goals of this collaboration were:
- Process window set up Metallurgical feasibility.
- Define deposition strategy to deposit WC in each area.
- Manufacture a demonstration part.
The main constraints they faced were:
- No materials in the insert locating.
- Single bead Width should be approx. 2,5 mm.
- Minimise the pre-processing time.
- Avoid metallurgical defects.
Solution
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.
Execution
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.
Host Role (IREPA Laser)
Provided AM‑DED hardware, toolpath programming expertise, and collision simulation services .
Beneficiary Role (Technogenia)
Defined metallurgical requirements, validated process windows, deployed deposition strategies, and evaluated outcomes .
Results of the Colaborration
Improved wear resistance for drilling heads
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
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.
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