Laser Metal Deposition

In conventional laser metal deposition, the laser beam heats up the workpiece locally, creating a weld pool. Fine metal powder is sprayed directly into the weld pool from a nozzle in the processing optics. This fine metal powder melts there and combines with the base material. A layer of approx. 0.2 to 1 millimetre thickness remains. In this way, beads form that are welded to one another, which then form structures on existing base bodies or entire components. If required, many layers can be built up one on top of the other. Laser metal deposition can create high build or volume rates of multiple cm³/min on 3D surfaces, with feed rates of 500 mm/min and as high as multiple metres/minute. To apply lines, areas and shapes, the automatically controlled processing optics move over the workpiece. An intelligent sensor system ensures that the layer thickness is even everywhere at all times. 

With high-speed laser metal deposition, the powder particles are already heated to almost melting temperature above the substrate surface. As a result, less time is required for melting the powder particles. The result: significantly increased processing speeds. Due to the lower heat input, high-speed laser metal deposition also enables the coating of very heat-sensitive materials such as aluminium or cast iron alloys. The HS-LMD process can create high surface rates up to 1500 cm²/min on rotationally symmetrical surfaces. This achieves feed rates of hundreds of metres/minute.

Upgrade your components – with a protection layer against corrosion or wear. Laser powder metal deposition creates coatings that harden your components and make them resistant to salt water, chemicals and weather. In contrast to conventional processes such as thermal spraying, the workpiece is only exposed to low thermal loads, so that there is only very little distortion – if at all. With LMD, a wide variety of material mixtures and layer structures is possible. For example, you can save production costs by using inexpensive materials for the component and then coating it with a high-quality coating.

Laser metal deposition opens up wide-ranging design freedom in the individual manufacture of components, above all in comparison to generic press moulds. By using laser metal deposition with filler material, completely new structures can be formed, or the shape and surface of existing components can be modified. Large components which do not fit in the build chamber of a 3D printer can also be completely generated in this way.

Seeking more added value? Repair expensive components or tools quickly and easily with laser powder metal deposition. Minor and major damage can be repaired quickly and almost imperceptibly. Design changes are also possible. This saves you time, energy and material. This is particularly worthwhile for expensive metals such as nickel or titanium. Typical application examples are turbine blades, pistons, valves, shafts or tools of all kinds.

Laser metal deposition is also suitable as a joining process – for example to bridge gaps of several millimetres. This creates uniform, tight seams – completely without post-processing. The coaxial powder feed makes this welding process three dimensional and independent of direction, giving you flexibility in the production chain. You can also use laser metal deposition to join different materials, such as steel and cast aluminium. Batteries for electric motors, for example, can be welded in this way.