Automation of a laser welding system for additive manufacturing

Abstract

This paper presents the benefits and challenges of using a standard robotised laser welding cell for additive manufacturing (AM). Additive manufacturing, sometimes denoted 3D-printing or rapid prototyping, has lately met strong interest in several areas of society, and a variety of technologies and materials have been in focus. The current paper summarises automation efforts for AM of advanced aero engine components using high power laser with welding optics as power source for melting metal wire and using an industrial robot for obtaining a 3-dimensional feature shape. The challenges are related to the process itself encountering high and repeated temperatures with melting and solidification of the metal as the main players. The major research solutions discussed in this paper are related to automation issues for obtaining a stable process and to have control of the temperatures and temperature changes that the metals encounter during the process. The solutions are successfully implemented in an industrial laser welding cell.