Laser-Based Repair System Reclaims High Value Military Components

摘要

Repair operations such as welding extend the life of high-value components in aircraft, tanks, and other military vehicles. In many cases, however, high-temperature welding processes will distort and weaken delicate metal components. Deemed irreparable, these expensive components are scrapped and replaced with new parts. Due to the age of some weapon systems, many times it is difficult locating new parts via the supply chain. To reclaim damaged parts, military facilities are turning to a new repair technique called Laser Engineered Net Shaping, or LENS'. In a LENS machine, designed by Optomec Inc. (Albuquerque, NM), a laser beam is directed towards a small area on a damaged metal component, producing a molten puddle. A nozzle blows metal powder into the puddle, which quickly solidifies creating a metallurgical bond with the part. A repair tool path is created using a vision system to deposit the lines of metal, guided by a computerized blueprint. LENS deposits one layer on top of another until it has created the desired repair. The LENS process induces much less heat into a part than conventional welding techniques, greatly reducing the heat-affected zone (HAZ). Critical areas of a part can be compromised with distortion and cracking by the formation of a large HAZ. LENS can repair components that cannot take the heat from other welding processes. What's more, LENS produces fully dense features with greater strength and ductility than conventional welding methods. The process is also much faster, more cost- effective, and wastes less material than its competitors. By giving new life to high-priced Abrams M1 tank engine components, LENS is saving DoD millions of dollars a year. The savings are sure to grow as more repair facilities adopt the technology to rescue damaged metal parts from the scrap heap.