Coaxial laser wire cladding head COAXwire

COAXwire – Cladding, repair and additive manufacturing using wire as feedstock material

Coaxial laser wire cladding head COAXwire
© Fraunhofer IWS Dresden / Frank Höhler
Coaxial laser wire cladding head COAXwire
Surface cladding with best as-welded surface quality
© Fraunhofer IWS Dresden / Jürgen Jeibmann
Surface cladding with best as-welded surface quality
Coated and generatively manufactured components of various metal alloys
© Fraunhofer IWS Dresden / Frank Höhler
Coated and generatively manufactured components of various metal alloys

The new coax laser cladding head COAXwire provides omni-directional welding performance for the use of metallic wires as filler material. As basic principle, the beam splitting optic divides the collimated laser beam into three separate beams, which are subsequently focused onto a circular focal point. At a fixed magnification factor of 1:3, the focus diameter is defined by the used fiber diameter. The optical elements are located in such a position that the wire supply runs exactly in the center axis of the laser beam. Thereby, the wire penetrates into the center of the laser-generated melt pool resulting in a perfect independence of the welding process from welding direction and gravity. All technical welding positions can be performed as important advantage of that configuration.

For fail safe operation, the cladding head contains a wire feed sensor as well as an automatic safety switch-off, which comes into action in case of collision or malfunction. Additionally, the compact construction allows the easy integration into CNC machines and robotic systems. Commercially available wires and cored wires can be used as well as normal wire feeding systems coming from the classic welding technology.


Application

The cladding head has been especially constructed for such applications, in which contours or 3D structures have to be generated, but which do not allow a powder use. Further advantages are a full material efficiency, improved operational safety and health protection. Examples here are protective coatings made of INCONEL, 3D structures on aluminum tools and repair coatings with steel wires.


Technical data

  • suitable lasers: fiber and disc lasers; diode lasers of adequate beam quality
    (< 30 mm mrad, fiber with NA 0.1); PL ≤ 4 kW
  • wire diameter: 0,4…1,6 mm
  • weight: 13 kg
  • outer dimensions WxDxH: 160 x 210 x 500 mm
  • media connections: coolant, shielding gas
  • interfaces: safety switch-off, optionally: CCD camera and temperature monitoring of melt pool
  • welding performance: deposition rates 2D: ≤ 3 kg/h,
    build-up rates 3D: ≤ 250 cm3/h