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Proceedings Paper

New developments in surface technology and prototyping
Author(s): Thomas Himmer; Eckhard Beyer
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Paper Abstract

Novel lightweight applications in the automotive and aircraft industries require advanced materials and techniques for surface protection as well as direct and rapid manufacturing of the related components and tools. The manufacturing processes presented in this paper are based on multiple additive and subtractive technologies such as laser cutting, laser welding, direct laser metal deposition, laser/plasma hybrid spraying technique or CNC milling. The process chain is similar to layer-based Rapid Prototyping Techniques. In the first step, the 3D CAD geometry is sliced into layers by a specially developed software. These slices are cut by high speed laser cutting and then joined together. In this way laminated tools or parts are built. To improve surface quality and to increase wear resistance a CNC machining center is used. The system consists of a CNC milling machine, in which a 3 kW Nd:YAG laser, a coaxial powder nozzle and a digitizing system are integrated. Using a new laser/plasma hybrid spraying technique, coatings can be deposited onto parts for surface protection. The layers show a low porosity and high adhesion strength, the thickness is up to 0.3 mm, and the lower effort for preliminary surface preparation reduces time and costs of the whole process.

Paper Details

Date Published: 3 March 2003
PDF: 7 pages
Proc. SPIE 4831, First International Symposium on High-Power Laser Macroprocessing, (3 March 2003); doi: 10.1117/12.497613
Show Author Affiliations
Thomas Himmer, Fraunhofer Institut fuer Werkstoff-und Strahltechnik Dresden (Germany)
Eckhard Beyer, Fraunhofer Institut fuer Werkstoff-und Strahltechnik Dresden (Germany)
Technische Univ. Dresden (Germany)


Published in SPIE Proceedings Vol. 4831:
First International Symposium on High-Power Laser Macroprocessing
Isamu Miyamoto; Kojiro F. Kobayashi; Koji Sugioka; Reinhart Poprawe; Henry Helvajian, Editor(s)

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