12/30/2015 | 1 MINUTE READ

Hybrid Applications Include Complex Components, Repair, Coating and Large Parts

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Machine maker expects hybrid to excel in work that represents “new possibilities” from what powder-bed machines are able to do.

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DMG MORI’s Lasertec 65 3D five-axis milling machine is equipped with a powder nozzle and 2-kW diode laser for laser deposition welding. Fully automatic change-over between milling and laser operation makes the machine suitable for complete machining of complex components, even with undercuts, as well as repair work, application of coatings, moldmaking, aerospace and medical applications. The machine is capable of producing complete 3D components with diameters ranging to 19.69" (500 mm). The machine and process are operated and controlled via the DMG MORI CELOS operating panel which is combined with the Siemens 840D SolutionLine Operate CNC.

The laser additive head, complete with powder deposition head and cooling, is attached into the standard HSK toolholder of the milling spindle. A diode laser source welds metal powder in layers, forming a high-strength welded bond with the base surface. According to the company, the process fuses the material without pores or cracks, forming a 99.95 percent dense deposited material. The coaxial nozzle which combines the laser beam and transports the powder with an inert gas, which at the same time prevents oxidation during the build-up process. After cooling, a layer of metal forms which can be machined mechanically. It is possible to build up material in lines of 1.6 or 3 mm, depending on nozzle geometry.

The head can be automatically parked outside the working area in a secure station while milling operations are being carried out in the working area of the machine. The additive process can be alternated with machining, making it possible to create parts with machined features that would not be possible to reach with a milling cutter after building. With a deposition rate as fast as 2.2 lbs/hr., the laser deposition welding capability is said to be as much as 10 times faster than building parts in a powder bed. The machine can also be filled with two different materials and changed over within a few minutes, enabling one material to be deposited after another. 

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