CLAD Process

(Additive Manufacturing)
 How it works

General
Metallic powders are injected into the CLAD nozzle to form a uniform jet. The powders melt and
fuse as they move across the laser beam, resulting in a uniform and dense deposit.

Displacement

Injection nozzle of the powder

Material deposited

Laser beam +
Metallic powder
Substrate

Video link : http://www.beam-machines.com/index.php?p=videos&hl=fr_FR

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 How it works
General

Optimization of the coupling by an adapted arrangement 4

 How it works
Advantages and process performance

Complexity and geometric resolution: Processing of surface and volumes

in 5 axis continuous with resolutions ranging from 600μm to several mm in width and 100μm to
several mm in height.
Caractéristiques
Adaptability and flexibility: Manufacturing of parts according to CAD files (generated by the
software PowerCLAD).

Reduced of finish time: Operations of machining and thermal treatments are limited

Control of the deposited materials: Functionally Gradient of Materials (FGM), localized

deposits of expensive materials.
Deposition efficiency: Up to 90%

High : Metallurgical quality is similar to casting parts (No crack, or bonding failure and very low
level of porosities). High mechanical strength with the very fine microstructure (rapid
solidification).
Sustainable Development: Using the right material needed, a precise control of the deposited
materials, and powder recycling.
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 Clad amongst other am technologies

• rapid manufacturing of metallic parts

– many different industrial processes

Without melting With melting

Melted
Powder on Powder on Powder
Metal sheets wire
bed bed deposition
deposition

SLS SLM DMD

(Selective Laser LOM (Selective (Direct Metal
Sintering) Laser Melting) Deposition)
(laminated
objects CLAD
3D Printing EBM
manufacturing) (electron
(Construction Laser
beam melting) Additive Directe)
 Quality evaluation

Very low level of pores (≈100% dense)

AISI 316L Ti alloy

Mechanical properties of a thin wall

AISI 316L

Traction X

Base material

Base material

Base material
Cast material

Cast material
cast material
Z Z Z
X X X

Mechanical resistance
Traction Z similar to base material
 Mechannical properties of a thick part
Tensile tests
Powder catchment efficiency
before machining: Re [MPa] Rm [MPa] A%

89% MacroCLAD 220 478 45

Reference 195 450-700 45

Material : SS 316L
Construction duration : 7min21s
Melted powders mass: 157.6g
Injected powders mass : 176.6g
 Technological possibilities

3D Manufacturing

Evolutive profil Manifold Ball Style exercise

Ti-6Al-4V Ti-6Al-4V 316L Ti-6Al-4V
H=100mm H=100mm 5 axes continus 5 axes continus
Time: 22min Time : 45min H = 200mm – 2h
Video link : http://www.beam-machines.com/index.php?p=videos&hl=fr_FR 6
 Technological possibilities

Adding Functions

Technological possibilities

Ø tube : 80mm Manufacturing time for 1 blade : 4min26s

Material : Inox 316 L
Deposite :- Width for two deposits(≈ 5 mm)
- Height 20 mm 7
 Technological possibilities

Repairing

repair of worn labyrinth seal

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 Technological possibilities

New repairs of metallic

parts
(worn labyrinth seal)

1st manufacturer of machine who have qualified the

process CLAD in aeronautics

4 types of parts repaired and qualified

Two types of new parts in qualification

400 parts repaired and returned to flight

First piece began its second cycle repair in August 2012

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 Metallurgical properties
General

Control of Hardness of the materials recharged

Very low level of porosity(< 0.01%)

Control of the dilution

Metallurgical quality is similar to wrought material

No crack, or bonding failure

Control the oxidation of sensitive materials as titanium alloys by using global
or local protections

Wall recharged with Ti-6Al-4V

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 Metallurgical properties
Metallic materials used (in progress)

Materials tested Type of application tested CLAD CLADDING

SS 316L Corosion resistance +++ +++
Cp Ti Bio-medical applications +++
Ti-6Al-4V Manufacturing and bio-medical applications +++ +++
Ti6242 Aircraft Parts and Repair +++ +++
Or jaune 750/1000 Jewellery ++ +
Base Cu Surface reinforcement ++ +++
Alliages Al (SI, …) Repair + ++
INCO 718 High temperature resistance +++ +++
INCO 625 Parts for aircraft +++ +++
stellite 1 Abrasion resistance NT +
Stellite 6, 12, 21, 25 Abrasion resistance ++ +++
WC + base Ni, Co, … Abrasion resistance NT +++
Tool Steels H13, D7, T15 dies, molds, ... NT ++
Tool Steels CPM 10V, M2 dies, molds, ... +++ +++
Waspaloy Parts for aircraft ++ ++
SS 410, 440, … Corosion resistance NT ++/+++
INCO 713 Repair ++ ++
Hadfield steel Abrasion resistance NT +++
NT=Not Tested
 FAO software (PowerCLAD)

%
;------- { Séquence d'armement laser }
OQ 1 1 ;Armement laser IPG
G04 P0.5
OQ 1 0
OA 6 10000 ;Puissance (0-10000 -> 0-200W)
OQ 2 1 ;Modulation ON
Post-processing OQ 3 1 ;Emission ON
;Programme CN
OQ 2 0 ;Modulation OFF
OQ 3 0 ;Emission OFF
G code generation M81 ;Désactivation des fonctions

Calculation of the tool parts

Digital preparation of the part

(slicing in sub-elements, strategy selection)

Import digital definition

(STEP, IGS, DGK)
For more information contact
IREPA LASER
www.irepa-laser.com