Fraunhofer Institute for Production Systems and Design TechnologyWire-based directed energy deposition for repair and reconditioning
Scan-based Repair Using Laser Cladding
Repair complex tools, molds, and components based on scan data
How does scan-based repair using laser cladding work?
Scan-based repair using laser cladding is a modern technology used to recondition complex tools, casting molds, forged parts, and expensive individual components. It can be used to restore component geometry without the need for a CAD model. Thus, damaged components can be repaired using a fully digital process chain.
Integrated scanner
The welding system is equipped with an integrated scanner. This allows the component to be positioned in the system and digitized immediately. The scan data is then processed and the areas to be repaired are identified. The robot’s CAM paths are planned on the derived surfaces from the scan and finally transferred to the system. Welding can then begin immediately without any further changes.
Laser cladding with wire
After preparation, the repair is carried out using wire-based laser cladding. Unlike powder-based laser cladding, wire is easy to handle and allows for a clean welding process. The hot wire option can additionally be used to preheat the wire, thus reducing the heat input into the base material. This enables the welding of difficult-to-process materials.
Digital process chain for component repair
Innovative surface and volume reconditioning using laser wire DED.
- Scanning instead of CAD – the integrated scanner eliminates the need for original design data
- Maximum resource efficiency – 100 percent material utilization thanks to wire-based welding
- Protection of the base material – thanks to the hot wire option
- More than just repair – geometries can be adapted or redesigned using additive DED technology
Advantages of scan-based repair using laser cladding
- Reduce costs – targeted repair of worn molds and components instead of purchasing new ones
- Remain flexible – robot guidance enables maximum geometric freedom
- Longer service life – reduced wear thanks to increased surface hardness
- Greater efficiency in use – longer service life thanks to optimized material selection
Our services related to scan-based repair using laser cladding
Repairing complex tools, molds, and components is based on scan data and can be used for a variety of mechanical engineering and mold-making applications:
- Mold making: Repair of worn molds with the potential to adjust the geometry through additive repair
- Energy sector: Welding of even demanding superalloys possible
- Plant engineering and process industry: Repair of complex components with customized tools to improve service life
What we offer:
- We offer customer-specific feasibility studies. Our services include developing a repair strategy and process parameters, as well as deriving a procedure for implementing the technology in your company.
- We also optimize existing repair process chains to maximize the potential of wire-based repair.
- We modify existing tools by welding on new features.