Path planning and process control for coaxial laser wire buildup welding
Additive processes offer the possibility of near-net-shape manufacturing of components with locally adapted mechanical properties, which can be optimized by downstream process steps. This leads to a double conservation of resources, on the one hand by minimizing the use of raw materials for component manufacture and on the other hand by ensuring that the component functions in accordance with the load.
Laser cladding with wire is a technology from 3D printing for manufacturing components from various metals. In contrast to other additive laser processes, this new technology has the advantage that the metallic semi-finished product is fed in wire form. This makes the process much cheaper and easier to handle than powder-based processes. In contrast to other wire-based processes, here the metal wire is fed into the melt pool coaxially with the laser beam, which brings decisive advantages in terms of directional independence and collision avoidance.
This project aimed to optimize the entire process chain for additively manufactured, functionally integrated components, enabling the cost-effective and resource-efficient production of near-net-shape parts. To achieve this, research focused on advancing the innovative coaxial laser wire deposition welding process.
Conventional path planning methods cannot guarantee high reliability from the very first component, as the complex interaction between the melt pool and its surroundings cannot be accurately predicted without excessive effort. At the same time, productivity is constrained by the deposition rate, which is limited by the metal’s inherent thermal conductivity and the transfer of heat from the laser-generated melt pool to the wire. This project sought to address these limitations and enhance both the applicability and efficiency of the process.
More than 300 additive printers in a single factory: By building the world's largest additive manufacturing facility, the mid-sized company Precitec from Gaggenau achieved revenues in the double-digit million range. This success is rooted in research conducted at the Innovation Campus Mobility of the Future. There, fundamental process principles were developed and rapidly brought to industrial maturity through a research partnership between the Institute for Laser Tools at the University of Stuttgart and Precitec. The resulting technology is not only more cost-efficient, sustainable, and high-performing but also opens up new business opportunities for the company and creates jobs.