This presentation addresses the development of Laser Wire Directed Energy Deposition (LW DED) at Oak Ridge National Laboratory (ORNL). LW DED is a novel additive manufacturing (AM) process that is gaining attention in various sectors, especially aerospace, that can produce large scale components with low Buy-to-Fly ratios (B:F) at high deposition rates, low costs, and with reductions in lead times. The LW DED system consists of a 20kW fiber delivered diode laser, a 6-axis KUKA robotic arm, a wire feeder, an enclosure chamber, and a laser line scanner. A control system is being developed in-house to increase the efficiency of the technology and resulting quality of the components. For example, maintaining bead geometry, i.e. height, is critical for good productivity.
The B:F is the mass of the initial workpiece to that of the finished component. The existing method to manufacture large structures such as stiffened panels and wing ribs is to machine them from large billets or forgings. Typically B:F are 15 to 20, but can be as large as 50 to 60. LW DED is capable of producing components with B:F as low as 1.2. Also, the mechanical properties of LW DED Ti-6Al-4V are comparable to other AM technologies and wrought properties (annealed condition) for the same alloy. Further, distortion models are being developed. Case studies will be presented with a special focus on B:F, deposition rates, and properties.
- Determine the suitability of applying Laser Wire DED to produce aerospace components
- Applicable for manufacturing aerospace components with low cost, high deposition rates along with low material wastage
- Make decisions on equipment and define business case studies
Why Is It Important?
Laser Wire Directed Energy Deposition is one of the novel additive manufacturing (AM) processes that is gaining attention in various sectors, especially aerospace, that can produce large scale components with low buy-to-fly ratios (B:F) at high deposition rates, low costs and with a reduction in lead time.