Laser deposition welding

Laser metal deposition is a generative manufacturing process for metals, which is usually referred to internationally as “laser metal deposition” (LMD). A laser applies thermal energy to the component surface and creates a molten pool. The introduction of wire or powder-based filler materials into the process creates weld seams on the base material. This mechanism can be used to coat surfaces or create three-dimensional structures. The process is widely used to create complex objects or repair expensive components.

The ProFocus1000 laser system from Oscar PLT GmbH is used for laser cladding at the Hanover Underwater Technology Center. It is characterized by its compact design, which is due to the use of diode lasers. Further advantages are the simple changeover between wire and powder as an additional material for the process and automatic height control by means of an integrated process camera. The laser is guided by a robot system from Kuka Deutschland GmbH, which consists of the KR50 R2100 manipulator and the DKP400 V2 turn/tilt positioner. The system's eight degrees of freedom enable complex structures. In addition, the system offers a wide range of applications in the functionalization of semi-finished products or the repair and reconditioning of cost-intensive components.

Technical data

ProFocus 1000 laser system

Laser class	4
Laser power	100 - 1000 W
Wavelength	915 nm ánd 980 nm (±20 nm)
Focus diameter	Ø 1 mm
Welding wire	Ø 0,8 – 1,2 mm
Roughening rate	up to 1 kg/h
Heating current for hot wire	up to 150 A
Flux fraction	45 - 150 µm
Flux utilization	ca. 85 %

Robot system consisting of KR50 R2100 and DKP400 V2

Number of axles	8
Nominal load capacity of the manipulator	50 kg
Position repeatability of manipulator	±0,05 mm
Nominal load capacity of the turn-tilt positioner	400 kg
Position repeatability DKP	±0,06 mm
Nominal welding current (100 % ED)	430 A
Nominal welding current (60 % ED)	500 A