The best of both worlds

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Yamazaki Mazak Deutschland GmbH

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Coaxial inert gas prevents oxidation during the build-up process

According to DMG-Mori, the machine first deposits the metal powder – stainless steel or different aluminium or nickel-based alloys for example – on a base material, one layer at a time, by means of a powder nozzle. It is then fused with the base material by means of the laser so that it is free from pores and cracks. A coaxial inert gas prevents oxidation during the build-up process. After cooling, a layer of metal forms, which can then be machined mechanically. The build-up rate is said to be 1 kg/h. “This means that laser deposition welding is ten times as fast as laser fusing in a powder bed,” emphasises Lell. “Wall thicknesses lie between 0.1 and 5 mm.” In contrast to laser fusing in a powder bed, laser deposition welding using a metal powder nozzle enables large parts to be manufactured. Complex 3D contours can also be generated layer-by-layer without supporting geometry.

Hamuel has been offering the “Hybrid” option for the five-axis turning and milling centres in its HSTM range for about a year. “As standard, the add-on includes the laser beam source with cooling, a special laser fume extraction system, adaptive software including measuring probes, the laser tool and a docking station,” reports Alexander Pieler, Manager Global Key Account at Hamuel Maschinenbau GmbH & Co. KG. “The hybrid machine works additively, that is to say by adding material in the form of metal powder, and adaptively, which means it calculates and produces one or more CNC programs before machining based on measured values,” he continues. “In-process measurement after laser deposition welding and finishing by means of metal removal ensures that the original shape of the component is achieved every time without undercuts or transitions.”

Ideally suited for the repair of turbine blades

The design advantages can be seen at Hamuel in the horizontal machine layout for the rotary axes. “These are ideally suited to the repair of flow components such as turbine blades or blisks,” stresses Pieler, “as the workpiece does not have to be positioned and moved by means of a rotary/swivel table.” The component accuracies that can be achieved and the dynamic response of up to seven axes acting simultaneously are significantly greater as a result. In addition, horizontal clamping of the workpiece means that the torques acting during machining are very small compared with vertical machining centres.

Business conditions good, prices and payment conditions remain tough

According to Pieler, the highly compact laser welding unit with HSK interface can be moved in and out by means of the integral tool changer. The inert and carrier gases, the metal powder and the power supply to the laser tool are connected via a patented interface. “This interface is so universal that it also allows alternative machining processes such as laser drilling, laser marking, laser-assisted metal cutting or laser hardening.”

Mazak, too, embarked on generative manufacturing at Jimtof 2014 in Tokyo. With the Integrex i-400 AM multifunctional machine, metal powder is fused using a fibre laser. Coating heads apply the molten material layer-by-layer. The component is then finish-machined. The coating heads are fitted in the machine’s tool magazine and can be loaded into the milling turret by conventional automatic tool changers. The Japanese offer two types of coating head: a high-speed head and a precision head.

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