Most direct laser deposition (DLD) processes utilisemetallic powders to obtain near net shape objects. Onthe other hand wire feeding has been used in manylaser-cladding applications. Each feeding method hasits own advantages and disadvantages. Wire feedinglaser deposition typically has higher deposition rateand higher material usage rate than the powder feedingdeposition process whilst powder feeding gives bettergeometry control. In this study a new approach isinvestigated by combining wire and powder feeding toachieve higher build rate and higher material usageefficiency whilst maintaining the geometry accuracy.Single layer clad build by the three methods arecompared and analysed in terms of cost, catchmentefficiency, surface roughness and microstructure. A 1.5KW diode laser is used to deposit 316L steel. Theresults showed that by combining both wire andpowder, higher catchment efficiency is achieved, thatsurface roughness is increased but remains constant forall the worked out parameters, that microstructureremains the same for all the three deposition methods.A comparison between the three methods is describedand its characteristics presented.
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