Application of 3D laser manufacturing in fabrication or repair of high-value metal component for the foundry industry

AbstractLaser direct metal deposition has proven to be successful in the manufacturing of 3D parts. In this process, the required geometry is built up layer by layer on overlapping laser clad beads. The object of the study is the manufacturing and repair of the blades of a sand kneader-mixer. Though made of carbon steel as bulk material, this element includes a protective ceramic coating with high wear resistance covering the more exposed surface in order to cope with severe wear service. However, detachment of this coating is often observed therefore diminishing its service life and leading to replacement costs. As an alternative to substitution by a new part, 3D laser manufacturing was considered for repairing. The procedure involves both refurbishing steel part and depositing a metal matrix composite (CrNi-WC) as wear resistant coating. Laser deposition of a graded metal-ceramic coatings structure was designed and tested so as to avoid cracking susceptibility of the fragile material. Software developed...