Laser metal deposition process of metals, alloys, and composite materials

225 Pages·2018·11.8 MB·English

by  Mahamood

Engineering Materials and Processes
Rasheedat Modupe Mahamood
Laser Metal
Deposition Process
of Metals, Alloys,
and Composite
by Finite Element and
MSofat Ctomepruitiangl Msethods
123
Engineering Materials and Processes
Series editor
Brian Derby, Manchester, UK
More information about this series at http://www.springer.com/series/4604
Rasheedat Modupe Mahamood
Laser Metal Deposition
Process of Metals, Alloys,
and Composite Materials
123
Rasheedat ModupeMahamood
Department ofMechanical Engineering
Science
University of Johannesburg
Johannesburg
SouthAfrica
and
Department ofMechanical Engineering
University of Ilorin
Ilorin
Nigeria
ISSN 1619-0181 ISSN 2365-0761 (electronic)
Engineering MaterialsandProcesses
ISBN978-3-319-64984-9 ISBN978-3-319-64985-6 (eBook)
DOI 10.1007/978-3-319-64985-6
LibraryofCongressControlNumber:2017949169
©SpringerInternationalPublishingAG2018
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This book is dedicated to Almighty God.
Foreword
Additive manufacturing process is an advanced manufacturing technology that
offers lots of advantages to the manufacturing world, such as the ability to reduce
the buy-to-fly ratio in the aerospace industry. With the additive manufacturing
method, the complex part that could not be made using the traditional manufac-
turingprocesswithoutbeingbrokendownintosmallerunitscannowbemadeasa
singleunitobject.Theuseoftheadditivemanufacturingmethodhelpstoreducethe
weight of the manufactured component by eliminating the extra materials needed
for the assembly of the smaller units that the complex part is broken down into
when the traditional manufacturing processes were used. It also helps to reduce
productleadtime,andnewproductcaneasilybebroughtintothemarketusingthe
additive manufacturing technologies. Laser metal deposition process is an additive
manufacturing technology that is useful for the production of new part and the
repairofhigh-valuedcomponents.Anumberofindustriesarebenefitingfromthese
technologies such as the aerospace and the automobile industries. This book was
written by the author to highlight the importance of this exciting additive manu-
facturingtechnology.Iamalsoanexpertinthisfieldandhavepublishedanumber
of articles, book chapters and a number of conference papers, and I am in a good
position to recommend this book to you. This book will benefit the industries by
helpingthemtounderstandthecapabilityofthelasermetaldepositionprocess.The
upcoming researchers in the field of advanced manufacturing process and the
professionals in this field will also find this book to be of great benefit.
The author of this book has published widely in this field of research which
include journal articles, conference proceedings, book chapters and books. The
author is in a better position to write this book as an expert in this field. The book
began with introduction and the background of the laser metal deposition process.
This book contains ten chapters. This introduction will provide the adequate
background information for the readers and the new researchers in this field for
proper understanding of the additive manufacturing processes. The information
aboutlaserispresentedinChap.2.Laserplaysanimportantroleintoday’sworld.
The characteristics of laser that makes it important in the laser metal deposition
processwerewellexplainedinChap.2.Thiswillhelpthereadertounderstandhow
vii
viii Foreword
the properties of laser have helped in achieving what could not be achieved in the
pastintermsofmanufacturing.Thelasermetaldepositionprocesswasdescribedin
Chap. 3.The solidificationmechanism andthemicrostructural evolution werealso
fully explained in this chapter. Processing parameters have been found to play an
important role, and they have serious influence on the properties of laser metal
deposited materials. The different processing parameters that affect this additive
manufacturing technology are presented in Chap. 4. The use of laser metal depo-
sition process for metals and alloys is explained in Chap. 5 with the different
materials that have been successfully deposited. The use of laser metal deposition
fortheprocessingofcompositematerialsaswellasfunctionallygradedmaterialsis
explained in Chap. 6. A number of application areas exist for the laser metal
depositionprocess.Theauthorexplainedthedifferentapplicationareasforthelaser
metaldepositionprocessarepresentedinChap.7.Lasermetaldepositionprocessis
used in repair of high-valued part and as surface modification process to improve
thesurface propertiesofmaterialswhicharepresentedinChap.7.Casestudies on
theuseoflasermetaldepositionoftitaniumalloyandtitaniumalloycompositeare
presented in Chap. 8 to enable the reader to further understand this important
additive manufacturing process. The research progress in this field of laser metal
depositionprocessispresentedinChap.9.The bookendswiththefutureresearch
need and the summary of the book.
Haven read this book thoroughly and also being an expert in this field of
research,Iherebystronglyrecommendthisbooktothereadersbecauseofthegreat
benefitsthebookwillofferandthisbookwillhelpthenewresearcherstohavethe
basic understanding required to succeed in this research field. I am in a good
positiontowritethisforwardbecauseIamalsoanexpertinthisresearchfieldand
Iwantthereaderstotakefulladvantageofthissubjectbyreadingthisbook.Thisis
theonly book inthemarketright now that fullytreat this subject whichmakes the
book an important one.
Prof. Esther Titilayo Akinlabi
Department of Mechanical Engineering Science
University of Johannesburg
Johannesburg, South Africa
Preface
The laser metal deposition process is an important additive manufacturing process
that has a great potential of revolutionizing the way products are made and
remanufactured.Thisbookstartswiththeintroductionofthelasermetaldeposition
process and a brief background of the process. A detailed introduction of the laser
metaldepositionprocessispresentedinChap.1ofthebook.Laserhasanumberof
important characteristics that make its use in the laser metal deposition process an
important one. The basics of laser principle are explained in Chap. 2. The char-
acteristics of laser are also described in this chapter. The laser metal deposition
process is fully described in Chap. 3. The important processing parameters in the
laser metal deposition process are explained in Chap. 4. Laser metal deposition of
metals and alloys and the laser metal deposition of composites and functionally
graded materials are explained in Chaps. 5 and 6, respectively. The areas of
application of the laser metal deposition process are presented in Chap. 7. Case
studies on the processing of titanium alloy and titanium alloy composite using the
lasermetaldepositionprocessarepresentedinChap.8.Theresearchadvancements
inlasermetaldepositionprocessarepresentedinChap.9,whilethefutureresearch
direction and summary are presented in Chap. 10. This book is organized as
follows:
Chapter 1—Introduction of laser metal deposition process and a brief back-
ground of the process are discussed in this chapter.
Chapter 2—Laser is an important invention the has helped to change the way
many things are done this days. Laser is a unique source of light that is highly
coherentandhighlydirectional.Theseimportantlasercharacteristicsoflasermake
itpossibletocontroltheenergytoonlytheneededarea.Thebasicprincipleoflaser
and characteristics of laser are explained in this chapter.
Chapter 3—The full description of the laser metal deposition process is pre-
sented in this chapter. The creation of the melt pool and the solidification process
that results in the characteristics microstructures during the laser metal deposition
process are fully described in this chapter.
Chapter4—Processingparameterssuchaslaserpower,scanningspeed,powder
flowrateandgasflowrateareveryimportantinthelasermetaldepositionprocess.
ix
x Preface
The influence of each of these processing parameters on the developed materials
properties is explained in this chapter.
Chapter 5—A number of materials can be processed using the laser metal
deposition process, and this is one of the reasons why this additive manufacturing
processisanimportantone.Thelasermetaldepositionprocessofmetalsandalloys
is presented in this chapter.
Chapter 6—Theflexibilityofferedbythelaser metaldepositionprocessisinits
capabilitytoprocessmorethanonematerialatthesametimethatmakesitpossible
tobeabletoprocesscompositeandfunctionallygradedmaterials.Theuseoflaser
metal deposition process for composite and functionally graded materials is pre-
sented in this chapter.
Chapter 7—Laser metal deposition process, like any other additive manufac-
turing process, can produce three-dimensional object directly from the
three-dimensional computer-aided design data of the object by adding materials
layer by layer. The laser metal deposition process is also useful in the repair of
high-valued parts which cannot be achieved by any other process. The areas of
applications of the laser metal deposition process are explained in this chapter.
Chapter 8—Casestudies on thelaser metal deposition process oftitaniumalloy
andtitaniumalloycompositeandtheinfluenceoftheprocessingparametersonthe
evolvingpropertiesofthetitaniumandtitaniumalloyarepresentedinthischapter.
Chapter9—Progressintermsofresearchinthelasermetaldepositionprocessis
presented in this chapter.
Chapter 10 ends the book. The future research direction in the laser metal
deposition process and the summary of the whole book are presented in this
chapter.
Johannesburg, South Africa Rasheedat Modupe Mahamood