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Thursday, June 10, 2004 - 9:00 AM
MSA1.2

Advances in Laser Powder Deposition for Additive Manufacturing

J. W. Sears, South Dakota School of Mines & Technology, Rapid City, SD

Developments in Laser Cladding and Rapid Prototyping have led to Solid Freeform Fabrication (SFF) technologies that produce net shape metal components by laser fusion of metal powder alloys. These processes are known by various names such as: Directed Light Fabrication (DLFä), Laser Engineered Net Shaping (LENSä), and Direct Metal Deposition (DMDä) to name a few. These types of processes can be referred to as laser powder deposition (LPD). LPD involves fusing metal alloy powders in the focal point of a laser (or lasers) that is (are) being controlled by Computer Aided Design-Computer Aided Manufacturing (CAD-CAM) technology. LPD technology has the capability to produce fully dense components with little need for subsequent processing. This same technology is also proving to be very useful for the repair of gas turbine engine (GTE) components due to the high solidification rates and low heat input inherent in laser processing. Research and development of LPD is being conducted throughout the world. The list of facilities conducting work in this area continues to grow (over 25 identified in North America alone). This presentation will review the history behind these developments and show how they may be applied to the aerospace industry.