Wire laser additive manufacturing of a compressor impeller

Abstract

Wire-laser additive manufacturing (WLAM) is a process that involves continuously feeding a wire into a melt pool created by a laser beam to create 3D components. The process dynamics, which include the laser-material interaction and wire transfer mode, have an impact on the part quality. To provide a stable deposition along the building path and predictable deposit properties, good process control is essential. The usage of support structures in metal additive manufacturing is limited, which makes manufacturing overhangs and curved structures difficult. The project creates a strategy for creating complicated geometries with an appropriate slicing technique. For the Cone and Blade, MATLAB was used to construct radial sliced layers, while Slic3r was used to make horizontally sliced layers. We need to set the Laser Power, Deposition Speed, and Wire Feed Rate to a fixed number in the beginning so that the combination does not affect the surface finishing and the bead width is as expected. To begin, we placed the cone in a vertical position perpendicular to the Laser and rotated the C-axis while keeping the Laser stationary, whereas the blade was deposited by keeping the workpiece perpendicular to the laser so that radial deposition can take place. Apart from this, in this report, we have discussed the challenges faced in the deposition of compressor impellers.