Intelligent nozzle design for the Laser Metal Deposition process in the Industry 4.0

Abstract

Laser Metal Deposition (LMD) is an AM (Additive Manufacturing) process that enables to build 3D geometries or enhance the surface properties of the base material by the generation of a coating. With the aim of integrating the AM inside the Industry 4.0 trend and improve the quality of the resulting parts, smart nozzles are required. Therefore, authors have developed an intelligent LMD nozzle by means of the integration of various sensing and control systems in a continuous coaxial LMD nozzle prototype. The nozzle is capable of regulating the laser power based on the temperature measurement of the melt pool. Moreover, it adjusts the powder flux that reaches the processing area according to an algorithm that ensures a constant powder income per surface unit area. Lastly, the nozzle evaluates the geometry of the deposited clad using an optical sensor.