Laser Metal Deposition

The most versatile process: repairing, coating, joining and additive manufacturing – in one process.

High-speed Laserauftragschweißen (HS-LMD)

High speed laser metal deposition – even faster

Surface coating in a short time – extremely thin and efficient – with very high quality.

Overview

Advantages

Technology comparison

Operating principle

Areas of application

Demo

Products

Laser metal deposition – a process for various applications

Laser metal deposition is an additive manufacturing method for metals and metal-ceramic compounds. It can be used to generate or modify 3D geometries. The laser can also perform repairing or coating processes with this manufacturing method. In the aerospace industry, additive manufacturing is used to repair turbine blades. In tool construction and mold making, broken or worn edges and shaping functional surfaces are repaired or even armored locally. Bearing points, rollers or hydraulic components in energy technology or petrochemistry are coated to protect against wear and corrosion. Additive manufacturing is also used in automotive engineering. In this industry, large numbers of components are refined.

TRUMPF customers benefit from the broad portfolio of lasers and laser systems. We have many years of process expertise and services for numerous laser technology applications. Additive manufacturing can also be combined with laser welding or laser cutting.

The international term is usually "laser metal deposition", abbreviated LMD. The terms "Direct Metal Deposition" (DMD) or "Direct Energy Deposition" (DED) or "Laser Cladding" are also used.

What are the advantages of laser metal deposition?

Higher build rates

Laser metal deposition creates rough and very fine structures. High build rates are achieved in comparison to other methods in additive manufacturing.

Material range

In the process, several powders can be conveyed and supplied at the same time. This makes it possible to develop dedicated alloys or switch between materials. Sandwich structures are formed in this way.

Flexibility

Structures can be easily applied to 3D parts and uneven surfaces. Changes to the geometry are also easily possible.

Simple change of materials

Laser metal deposition makes it possible to change between different materials in a work process with ease.

Established method

Laser metal deposition is used to repair tools or components, for example in the aerospace industry. It is also used to apply thin layers for protection from corrosion and wear.

Innovative

Thanks to the magic of technology, maximum speeds of several hundred meters per minute can be achieved: high-speed laser metal deposition reveals its strengths in the coating of brake disks, for example.

How do the laser sources differ in the various LMD applications?

Laser metal deposition (LMD)

Conventional laser metal deposition is used for flexible coating, repair and additive modification of 3D components. Since no process chamber is required for this method, very large components can also be processed. The applied layers are metallurgically bonded to the substrate so that high strength – often comparable to standard grades – can be achieved.

High speed laser metal deposition (HS-LMD)

High speed laser metal deposition is based on the EHLA process (EHLA= extreme high speed laser metal deposition) developed by Fraunhofer ILT. It is suitable for coating large areas of rotationally symmetrical components with thin layers. As in conventional laser metal deposition, the applied layers are metallurgically welded to the substrate. Due to the very high processing speeds and the associated rapid cooling, higher strength levels are achieved. It can also be used to process materials that are considered difficult to weld (e.g. cast iron).

Laser metal deposition with green laser radiation

Laser metal deposition using green laser radiation is particularly effective for highly reflective materials such as pure copper, copper alloys, bronzes, aluminum alloys or precious metal alloys. Compared to the infrared wavelength range, the green wavelength has a significantly higher absorption; a much higher absorption can be achieved for pure copper and copper alloys. Compared to infrared wavelengths, additive manufacturing with green wavelengths enables higher densities and a near-net-shape construction with significantly lower laser power when processing copper alloys.

How do laser metal deposition and high-speed laser metal deposition work?

Process diagram - laser metal deposition

Laser metal deposition (LMD)

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 millimeter 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 meters/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.

High speed laser metal deposition (HS-LMD)

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 aluminum or cast iron alloys. The HS-LMD process can createhigh surface rates up to 1500 cm²/min on rotationally symmetrical surfaces. This achieves feed rates of hundreds of meters/minute.

Find out what our customers are excited about

We sometimes implement application ideas at our own expense. It can take a while before success comes; you have to tough it out.

Christoph Hauck

Chief Technology and Sales Officer at toolcraft AG

Go to success story

What is laser metal deposition suitable for?

TRUMPF application powertrain brake disk

Coating

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 for generating partial reinforcements

Additive manufacturing

Laser metal deposition opens up wide-ranging design freedom in the individual manufacture of components, above all in comparison to generic press molds. Durch Auftragschweißen mit Zusatzmaterial können komplett neue Strukturen entstehen oder bestehende Bauteile in Form und Oberflächenstruktur verändert werden. Large components which do not fit in the build chamber of a 3D printer can also be completely generated in this way.

Repair

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.

Joining

Laser metal deposition is also suitable as a joining process – for example to bridge gaps of several millimeters. 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 aluminum. Batteries for electric motors, for example, can be welded in this way.

Laser metal deposition and high-speed laser metal deposition in action

What products are suitable for laser metal deposition?

TruLaser Cell 3000

The compact and high-precision 5-axis laser machine allows you to remain flexible: you can perform welding, cutting, and LMD through fast process adapter changes.

To the product

TruLaser Cell 7040

Perfectly equipped – regardless of whether you want to process two or three-dimensional components or tubes. You can change flexibly between cutting, welding and laser metal deposition.

To the product

DepositionLine

Unlock new markets. Whether in coating, repair work or additive manufacturing – you get an individual solution consisting of beam source, powder feeder, optics and nozzles.

To the product

You may also find these topics interesting

Laser metal deposition of brake disks in accordance with the Euro 7 standard

Find out why high-speed laser metal deposition is the optimal choice for manufacturing Euro 7-compliant brake disks - and about the new standard in the manufacture of brake disks.