High Speed Laser Cladding Repair Process Development

High Speed Laser Cladding Repair Process Development

This project seeks to expand upon the exploratory project, 18-02-RM-03 results to more fully vet the capabilities of HSLC and investigate additional additive repair applications that are challenging due to strength requirements, distortion requirements, and wear requirement. Limitations to the performance of the developed HSLC system will also be addressed, including design of a nozzle with HSLC in mind that incorporates additional cooling and improved powder focus. The technology solution that will be delivered at the end of the project is HSLC material system repair techniques, including a new powder nozzle design, and a general process guide to describe application of the repair methods. This project will reduce primary feedstock by 0.014 million metric tons (MMT) steel, 13.8 PJ energy reduction, 0.8 MMTCO2e. Assumptions based on preliminary results of 18-02-RM-03. 

Project Team:
Rochester Institute of Technology (RIT), Caterpillar Inc., Synergy Additive Manufacturing

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21-01-RM-5027

High Speed Laser Cladding for Hard Surface Replacement

High Speed Laser Cladding for Hard Surface Replacement

This project lays out a novel technique - high speed laser cladding - for remanufacturing high-strength components such as crankshafts and camshafts. While cladding is a proven technique for applying wear-resistant metal coatings In manufacturing, high-speed laser cladding increases productivity and significantly reduce the cost of applying the layers That will enable use of this technology in remanufacturing.

The new approach to cladding will result in increasing the reuse rate in engine remanufacturing from 70% to 95%, reducing annual embodied energy and emissions by 1.3 PJ and 44,000 metric tons, respectively.

Project Team:
Rochester Institute of Technology, Caterpillar Inc., Synergy Additive Manufacturing

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18-02-RM-03