Research

Fraunhofer develops EHLA ultra-high-speed laser material deposition process for coating metal parts

Researchers at the Fraunhofer Institute for Laser Technology (ILT) have developed a new additive manufacturing method for coating, and repairing, metal parts.

弗劳恩霍夫认为,技术,称为超high-speed laser material deposition (EHLA), has potential to replace current corrosion and wear protection methods such as hard chrome plating and thermal spraying.

该开发项目包括来自Fraunhofer和RWTH Aachen大学的研究人员,最近获得了Joseph von Fraunhofer奖。为了获得这项成就,EHLA研究人员 - 安德烈斯·加瑟(Andres Gasser)博士,托马斯·史波芬(Thomas Schopphoven)和格哈德·玛丽亚·贝克斯(Gerhard Maria Backes) - 被授予50,000欧元。

The EHLA developers, Thomas Schopphoven, Gerhard Maria Backes and Andres Gasser. Photo by Piotr Banczerowski for Fraunhofer.
The EHLA developers, Thomas Schopphoven, Gerhard Maria Backes and Andres Gasser. Photo by Piotr Banczerowski for Fraunhofer.

Ultra-high-speed laser material deposition

弗劳恩霍夫(Fraunhofer)解释说,EHLA过程以效率和速度既改进现有的腐蚀和磨损保护方法。Fraunhofer Ilt的小组经理Andres Gasser博士写道

现在,我们可以使用EHLA在短时间内在大型表面上在十分之一毫米的范围内施加薄层,同时是资源有效且经济的,

EHLA使用激光在熔体池上方融化金属粉末。这意味着液态金属滴入焊接池而不是烧结的颗粒。这是有益的,因为这意味着这些层更均匀,需要更少的材料融化。此外,弗劳恩霍夫(Fraunhofer)the component can be coated 100 to 250 times faster than with conventional laser material deposition” and without heating the substrate.

The Fraunhofer Institute for Laser Technology is certainly familiar with the use of lasers in additive manufacturing, as 3D Printing Industry learned earlier this year at conference discussing the use of系列生产激光器.

The EHLA process applied to a metal component. Photo via Fraunhofer ILT.
The EHLA process applied to a metal component. Photo via Fraunhofer ILT.

弗劳恩霍夫(Fraunhofer)表示,它为战斗腐蚀和磨损保护的替代方案提供了改进。由于硬镀铬的电镀会消耗大量的能量,并且在粘结和孔隙率方面具有缺点,而在所用材料方面,热喷涂可能非常浪费。相比之下,EHLA过程是非孔子的,从而改善了粘结并减少了裂缝和毛孔的可能性。EHLA技术还使用90%的材料,比热喷涂更节俭。

Repairing metal

有趣的是,Fraunhofer认为新的EHLA涂料方法可用于修复现有的金属零件。阿克伦大学已经探索了使用添加剂制造来维修金属组件。与飞机维护和维修公司合作之后,大学的NCercamp开发了一种超音速粒子沉积的方法which could have application in repairing metal aircraft components – if it receives FAA certification. Fraunhofer’s EHLA could similarly have such application for the ability to build up layers of metal on a part.

立即使用EHLA将试图解决Akron大学NCercamp估计的物质腐蚀成本4000亿美元每年。

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Featured image shows the EHLA process applying protective layers to a metal part. Photo by Volker Lannert for Fraunhofer ILT.