Additive Manufacturing
Diode sources for wire-based laser metal deposition and laser-assisted WAAM
Directed energy deposition (DED) builds metal parts layer by layer by melting a filler material as it is deposited. When the filler is a wire, the process reaches high deposition rates, uses almost all the material and can produce or repair large parts. The laser plays two roles: as the main energy source in wire-based laser deposition, or as an auxiliary source that improves arc deposition (WAAM).
Coaxial wire laser deposition
In wire-based laser deposition, the wire is fed along the axis of the head and several beams converge on it. This coaxial configuration makes the process independent of travel direction: with three beams, the bead geometry is symmetric in any direction [1]. Compared with powder, wire is cheaper per kilogram and a larger fraction of it is used [2].
| Parameter | Reference value (three beams, Ti-6Al-4V) |
|---|---|
| Total laser power (CW) | 1,4–2,0 kW [1] |
| Wire diameter | 1,2 mm [1] |
| Wire feed speed | 38–54 mm/s [1] |
| Dependence on travel direction | Not significant [1] |
Multi-beam heads need compact, powerful sources with a well-shaped beam on the wire. We supply diode stacks with micro-optics for wire laser deposition heads.
Laser-assisted WAAM
Wire arc additive manufacturing (WAAM) offers very high deposition rates, but its accuracy and surface finish are limited. Adding a laser beam to the arc (L-WAAM) stabilizes the melt pool, reduces spatter and improves bead accuracy, resulting in higher quality, better surface finish and higher productivity [3, 4].
In the COMSENSO project, funded by CDTI, we developed the high-power laser source for an L-WAAM cell that integrates the beam with a GMAW torch and closed-loop process control [4]. The project results add to those published in the literature:
| Result | Value | Source |
|---|---|---|
| Surface roughness | 20% better than WAAM (laser–GMAW) | [3] |
| Elongation | +34%, with reduced anisotropy (laser–GMAW) | [3] |
| Yield strength | +15 % (láser–GMAW) | [3] |
| Starting material | −67% in a multi-material steel and Invar mold, compared with the conventional process | [4] |
| Part weight | −34% in the same mold, thanks to design freedom | [4] |
We supply the direct diode source with its power and control electronics, including closed-loop temperature control with a pyrometer, ready for integration into hybrid laser–arc heads.
References
1. Mathenia R, McLain B, Sparks T, Liou F. A study of directionality effects in three-beam coaxial titanium wire-based laser metal deposition. Materials. 2024;17(13):3201. doi:10.3390/ma17133201
2. Ream S, Hay J, Walters C. High-power coaxial wire laser directed-energy deposition: an update. Industrial Laser Solutions (Laser Focus World), 23 de junio de 2021.
3. Kapil SK, Rajput AS, Sarma R. Hybridization in wire arc additive manufacturing. Front Mech Eng. 2022;8:981846. doi:10.3389/fmech.2022.9818
4. Proyecto COMSENSO. “El proyecto COMSENSO cierra su tercera anualidad con éxito”. Nota de prensa, 30 de septiembre de 2024. www.comsenso.es
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