Introduction to Laser Metal Deposition Process

Chapter
First Online:
Part of the Engineering Materials and Processes book series (EMP)

Abstract

Additive manufacturing process is an advanced manufacturing process that fabricates components through the addition of materials as against the labour and energy intensive manufacturing processes which are based on material removal, or on application of heat and pressure. Laser metal deposition process belongs to a class of additive manufacturing process that can be used to fabricate three dimensional (3D) computer aided design model of the part by adding materials in a layer wise manner. Apart from the fabrication of 3D objects, laser metal deposition process can also be used to repair broken down parts and for the fabrication of parts that are made of composite and functionally graded materials. This important additive manufacturing technology is comprehensively dealt with in this book. This chapter briefly introduced the additive manufacturing (AM) process, the various classes of the AM technologies, laser metal deposition process, and the advantages as well as the limitation of these technologies.

Keywords

Additive manufacturing Laser metal deposition Functionally graded material Advantages of LMD Limitations of LMD 
This is a preview of subscription content, log in to check access.

Notes

Acknowledgements

This work was supported by University of Johannesburg research council, University of Ilorin and the L’OREAL-UNESCO for Women in Science.

References

  1. 1.
    Mahamood RM, Akinlabi ET, Shukla M, Pityana S (2014) Evolutionary additive manufacturing: an overview. Lasers Eng 27:161–178Google Scholar
  2. 2.
    Scott J, Gupta N, Wember C, Newsom S, Wohlers T, Caffrey T (2012) Additive manufacturing: status and opportunities. Science and Technology Policy Institute. Available from https://www.ida.org/stpi/occasionalpapers/papers/AM3D_33012_Final.pdf. Accessed on 11 Oct 2016
  3. 3.
    Velasco MA, Lancheros Y, Garzón-Alvarado DA (2016) Geometric and mechanical properties evaluation of scaffolds for bone tissue applications designing by a reaction-diffusion models and manufactured with a material jetting system. J Comput Des Eng 3(4):385–397Google Scholar
  4. 4.
    Hull CW (1986) Apparatus for production of three-dimensional objects by stereolithography. US Patent 4575330Google Scholar
  5. 5.
    Husár B, Hatzenbichler M, Mironov V, Liska R, Stampfl J, Ovsianikov A (2014) Photopolymerization-based additive manufacturing for the development of 3D porous scaffolds. In: Biomaterials for bone regeneration. Woodhead Publishing, pp 149–201Google Scholar
  6. 6.
    Mitteramskogler G, Gmeiner R, Felzmann R, Gruber S, Hofstetter C, Stampfl J, Ebert J, Wachter W, Laubersheimer J (2014) Light curing strategies for lithography-based additive manufacturing of customized ceramics. Addit Manuf 1–4:110–118CrossRefGoogle Scholar
  7. 7.
    Zhou M, Liu W, Wu H, Song X, Yong C, Lixia C, Fupo H, Shixi C, Shanghua W (2016) Preparation of a defect-free alumina cutting tool via additive manufacturing based on stereolithography—optimization of the drying and debinding processes. Ceram Int. 42(10):11598–11602Google Scholar
  8. 8.
    Haidong W, Cheng Y, Liu W, He R, Zhou M, Shanghua W, Song X, Chen Y (2016) Effect of the particle size and the debinding process on the density of alumina ceramics fabricated by 3D printing based on stereolithography. Ceram Int 42(15):17290–17294CrossRefGoogle Scholar
  9. 9.
    Meteyer S, Xin X, Perry N, Zhao YF (2014) Energy and material flow analysis of binder-jetting additive manufacturing processes. Proc CIRP 15:19–25CrossRefGoogle Scholar
  10. 10.
    Gaytan SM, Cadena MA, Karim H, Delfin D, Lin Y, Espalin D, MacDonald E, Wicker RB (2015) Fabrication of barium titanate by binder jetting additive manufacturing technology. Ceram Int 41(5, Part A):6610–6619Google Scholar
  11. 11.
    Tang Y, Mak K, Zhao YF (2016) A framework to reduce product environmental impact through design optimization for additive manufacturing. J Cleaner Prod 137(20):1560–1572CrossRefGoogle Scholar
  12. 12.
    Gonzalez JA, Mireles J, Lin Y, Wicker RB (2016) Characterization of ceramic components fabricated using binder jetting additive manufacturing technology. Ceram Int 42(9):10559–10564CrossRefGoogle Scholar
  13. 13.
    Min H, Lee B, Jeong S, Lee M (2017) Fabrication of 10 µm-scale conductive Cu patterns by selective laser sintering of Cu complex ink. Opt Laser Technol 88:128–133CrossRefGoogle Scholar
  14. 14.
    Yan M, Zhou C, Tian X, Peng G, Cao Y, Li D (2016) Design and selective laser sintering of complex porous polyamide mould for pressure slip casting. Mater Des 111(5):198–205CrossRefGoogle Scholar
  15. 15.
    Konečná R, Kunz L, Nicoletto G, Bača A (2016) Long fatigue crack growth in Inconel 718 produced by selective laser melting. Int J Fatigue 92(Part 2):499–506CrossRefGoogle Scholar
  16. 16.
    Ahmadi A, Mirzaeifar R, Moghaddam NS, Turabi AS, Karaca HE, Elahinia M (2016) Effect of manufacturing parameters on mechanical properties of 316L stainless steel parts fabricated by selective laser melting: A computational framework. Mater Des 112:328–338Google Scholar
  17. 17.
    Bertoli US, Wolfer AJ, Matthews MJ, Delplanque JR, Schoenung JM (2017) On the limitations of volumetric energy density as a design parameter for selective laser melting. Mater Des 113:331–340Google Scholar
  18. 18.
    Paul BK, Voorakarnam V (2001) Effect of layer thickness and orientation angle on surface roughness in laminated object manufacturing. J Manuf Proc 3(2):94–101Google Scholar
  19. 19.
    Ahn D, Kweon J-H, Choi J, Lee S (2012) Quantification of surface roughness of parts processed by laminated object manufacturing. J Mater Process Technol 212(2):339–346CrossRefGoogle Scholar
  20. 20.
    Butt J, Mebrahtu H, Shirvani H (2016) Microstructure and mechanical properties of dissimilar pure copper foil/1050 aluminium composites made with composite metal foil manufacturing. J Mater Process Technol 238:96–107CrossRefGoogle Scholar
  21. 21.
    Ford S, Despeisse M (2016) Additive manufacturing and sustainability: an exploratory study of the advantages and challenges. J Clean Prod 137(20):1573–1587CrossRefGoogle Scholar
  22. 22.
    Sridharan N, Gussev M, Seibert R, Parish C, Norfolk M, Terrani K, Babu SS (2016) Rationalization of anisotropic mechanical properties of Al-6061 fabricated using ultrasonic additive manufacturing. Acta Mater 117:228–237Google Scholar
  23. 23.
    Hehr A, Dapino MJ (2017) Dynamics of ultrasonic additive manufacturing. Ultrasonics 73:49–66CrossRefGoogle Scholar
  24. 24.
    Faes M, Vleugels J, Vogeler F, Ferraris E (2016) Extrusion-based additive manufacturing of ZrO2 using photoinitiated polymerization. CIRP J Manufact Sci Technol 14:28–34CrossRefGoogle Scholar
  25. 25.
    Park S-i, Rosen DW (2016) Quantifying effects of material extrusion additive manufacturing process on mechanical properties of lattice structures using as-fabricated voxel modeling. Additive manufacturing. Available online at:http://0-dx.doi.org.ujlink.uj.ac.za/10.1016/j.addma.2016.05.006. Accessed on 27 Oct 2016
  26. 26.
    Raasch J, Ivey M, Aldrich D, Nobes DS, Ayranci C (2015) Characterization of polyurethane shape memory polymer processed by material extrusion additive manufacturing. Addit Manuf 8:132–141CrossRefGoogle Scholar
  27. 27.
    Ravi AK, Deshpande A, Hsu KH (2016) An in-process laser localized pre-deposition heating approach to inter-layer bond strengthening in extrusion based polymer additive manufacturing. J Manuf Proc 24(Part 1):179–185Google Scholar
  28. 28.
    Seppala JE, Migler KD (2016) Infrared thermography of welding zones produced by polymer extrusion additive manufacturing. Addit Manuf 12(Part A):71–76Google Scholar
  29. 29.
    Kakinuma Y, Mori M, Oda Y, Mori T, Kashihara M, Hansel A, Fujishima M (2016) Influence of metal powder characteristics on product quality with directed energy deposition of Inconel 625. CIRP Annals Manuf Technol 65(1):209–212CrossRefGoogle Scholar
  30. 30.
    Mazumder J (2017) 1—Laser-aided direct metal deposition of metals and alloys. In: M Brandt (Ed) Woodhead publishing series in electronic and optical materials. Woodhead Publishing, pp 21–53Google Scholar
  31. 31.
    Carroll BE, Otis RA, Borgonia JP, Suh J-o, Peter Dillon R, Shapiro AA, Hofmann DC, Liu Z-K, Beese AM (2016) Functionally graded material of 304L stainless steel and inconel 625 fabricated by directed energy deposition: characterization and thermodynamic modeling. Acta Mater 108:46–54Google Scholar
  32. 32.
    Shim D-S, Baek G-Y, Seo J-S, Shin G-Y, Kim K-P, Lee K-Y (2016) Effect of layer thickness setting on deposition characteristics in direct energy deposition (DED) process. Opt Laser Technol 86:69–78CrossRefGoogle Scholar
  33. 33.
    Wang Z, Palmer TA, Beese AM (2016) Effect of processing parameters on microstructure and tensile properties of austenitic stainless steel 304L made by directed energy deposition additive manufacturing. Acta Mater 110(15):226–235CrossRefGoogle Scholar
  34. 34.
    Bimber BA, Hamilton RF, Keist J, Palmer TA (2016) Anisotropic microstructure and superelasticity of additive manufactured NiTi alloy bulk builds using laser directed energy deposition. Mater Sci Eng, A 674(30):125–134CrossRefGoogle Scholar
  35. 35.
    Graf B, Gumenyuk A, Rethmeier M (2012) Laser metal deposition as repair technology for stainless steel and titanium alloys. Phys Proc 39:376–381CrossRefGoogle Scholar
  36. 36.
    Graf B, Ammer S, Gumenyuk A, Rethmeier M (2013) Design of experiments for laser metal deposition in maintenance, repair and overhaul applications. Proc CIRP 11:245–248CrossRefGoogle Scholar
  37. 37.
    Liu Q, Wang Y, Zheng H, Tang K, Li H, Gong S (2016) TC17 titanium alloy laser melting deposition repair process and properties. Opt Laser Technol 82:1–9CrossRefGoogle Scholar
  38. 38.
    Zhong C, Gasser A, Kittel J, Wissenbach K, Poprawe R (2016) Improvement of material performance of Inconel 718 formed by high deposition-rate laser metal deposition. Mater Des 98(15):128–134CrossRefGoogle Scholar
  39. 39.
    Paydas H, Mertens A, Carrus R, Lecomte-Beckers J, Tchoufang Tchuindjang J (2015) Laser cladding as repair technology for Ti–6Al–4V alloy: influence of building strategy on microstructure and hardness. Mater Des 85:497–510Google Scholar
  40. 40.
    Raju R, Duraiselvam M, Petley V, Verma S, Rajendran R (2015) Microstructural and mechanical characterization of Ti6Al4V refurbished parts obtained by laser metal deposition. Mater Sci Eng A 643(3):64–71CrossRefGoogle Scholar
  41. 41.
    Petrat T, Graf B, Gumenyuk A, Rethmeier M (2016) Laser metal deposition as repair technology for a gas turbine burner made of Inconel 718. Phys Proc 83:761–768CrossRefGoogle Scholar
  42. 42.
    Leino M, Pekkarinen J, Soukka R (2016) The role of laser additive manufacturing methods of metals in repair, refurbishment and remanufacturing—enabling circular economy. Phys Proc 83:752–760CrossRefGoogle Scholar
  43. 43.
    Ding Y, Dwivedi R, Kovacevic R (2017) Process planning for 8-axis robotized laser-based direct metal deposition system: a case on building revolved part. Robot Comp Integr Manuf 44:67–76CrossRefGoogle Scholar
  44. 44.
    Mahamood RM, Akinlabi ET, Shukla M, Pityana S (2012) Functionally graded material: an overview. In: Proceedings of the World Congress on Engineering (2012), vol III, WCE 2012, London, UK, July 4–6, pp.1593-1597Google Scholar
  45. 45.
    Mahamood RM, Akinlabi ET (2015) Laser metal deposition of functionally graded Ti6Al4V/TiC. Mater Des 84:402–410CrossRefGoogle Scholar
  46. 46.
    Muller P, Mognol P, Hascoet J-Y (2013) Modeling and control of a direct laser powder deposition process for functionally graded materials (FGM) parts manufacturing. J Mater Process Technol 213(5):685–692CrossRefGoogle Scholar
  47. 47.
    T-t Q, Dong Liu, Xiang-jun T, Chang-meng L, Hua-ming W (2014) Microstructure of TA2/TA15 graded structural material by laser additive manufacturing process. Trans Nonferrous Metals Soc China 24(9):2729–2736CrossRefGoogle Scholar
  48. 48.
    Durejko T, Ziętala M, Polkowski W, Czujko T (2014) Thin wall tubes with Fe3Al/SS316L graded structure obtained by using laser engineered net shaping technology. Mater Des 63:766–774CrossRefGoogle Scholar
  49. 49.
    Amado JM, Montero J, Tobar MJ, Yáñez A (2014) Laser cladding of Ni-WC layers with graded WC content. Phys Proc 56:269–275CrossRefGoogle Scholar
  50. 50.
    Kratky A (1937) Production of hard metal alloys. Patent # US 2076952Google Scholar
  51. 51.
    Harter I (1942) Method of forming structures wholly of fusion deposited weld metal. Patent # US 2299747AGoogle Scholar
  52. 52.
    Brown CO, Breinan EM, Kear BH (1982) Method for fabricating articles by sequential layer deposition. Patent # US 4323756AGoogle Scholar
  53. 53.
    Mehta PP, Otten RR, Cooper EB (1988) Method and apparatus for repairing metalin an article. Patent # US 4743733AGoogle Scholar
  54. 54.
    Jeantette FP, Keicher DM, Romero JA, Schanwald LP (2000) Method and system for producing complex-shape objects. Patent # US 006046426AGoogle Scholar
  55. 55.
    Griffith M, Schlienger M, Harwell L (1998) Thermal behavior in the LENS process. In: No SAND–98-1850C; CONF-980826, Sandia Natl Labs, Albuquerque, NM, USAGoogle Scholar
  56. 56.
    Griffith M, Schlienger M, Harwell L, Oliver M, Baldwin M, Ensz M et al (1999) Understanding thermal behavior in the LENS process. Mater Des 20:107–113CrossRefGoogle Scholar
  57. 57.
    Griffith ML, Hofmeister WH, Knorovsky GA, MacCallum DO, Schlienger ME, Smugeresky JE (2002) Direct laser additive fabrication system with image feedback control. Patent # US 6459951B1Google Scholar
  58. 58.
    Griffith ML, Keicher DM, Atwood CL, Romero JA, Smugeresky JE, Harwell LD et al (1996) Free form fabrication of metallic components using laser engineered net shaping (LENSTM). In: Proceedings of 7th Solid Freeform Fabrication Symposium, Austin, USA, pp 125–132Google Scholar
  59. 59.
    Selcuk C (2011) Laser metal deposition for powder metallurgy parts. Powder Metall 54:94–99. doi: 10.1179/174329011X12977874589924 Google Scholar
  60. 60.
    Costa L, Vilar R (2009) Laser powder deposition. Rapid Prototyp J 15:264–279. doi: 10.1108/13552540910979785 CrossRefGoogle Scholar
  61. 61.
    Mazumder J, Qi H (2005) Fabrication of 3-D components by laser aided direct metal deposition. Proc SPIE Int Soc Opt Eng, 38–59Google Scholar
  62. 62.
    Weerasinghe VM, Steen WM (1987) Laser cladding with blown powder. Met Construct 19:581–585Google Scholar
  63. 63.
    Mazumder J, Schifferer A, Choi J (1998) Direct materials deposition: designed macro and microstructure. Mater Res Innovations 3:118–131CrossRefGoogle Scholar
  64. 64.
    Choi J, Chang Y (2005) Characteristics of laser aided direct metal/material deposition process for tool steel. Int J Mach Tools Manuf 45:597–607. doi: 10.1016/j.ijmachtools.2004.08.014 CrossRefGoogle Scholar
  65. 65.
    Choi J (2002) Process and properties control in laser aided direct metal/materials deposition process. Manufacturing, vol 2002, ASME, pp 81–89. http://dx.doi.org/10.1115/IMECE2002-33568
  66. 66.
    Zhang K, Liu W, Shang X (2007) Research on the processing experiments of laser metal deposition shaping. Opt Laser Technol 39:549–557. doi: 10.1016/j.optlastec.2005.10.009 CrossRefGoogle Scholar

Copyright information

© Springer International Publishing AG 2018

Authors and Affiliations

  1. 1.Dep of Mechanical Engineering ScienceUniversity of JohannesburgJohannesburgSouth Africa

Personalised recommendations