LENS Deposition of Complex Geometries

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Date

2003

Authors

Gill, David D.
Griffith, Michelle L.
Reckaway, Daryl E.
Briner, Clifton F.
Abrams, Douglas G.

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Abstract

The Laser Engineered Net Shaping (LENS®) system at Sandia National Laboratories, a laser-based direct metal deposition process, was recently used for the fabrication of a complex prototype. The LENS process involved the challenges of adjacent areas of thick and thin cross section, overhanging unsupported features, high aspect ratios, and a hemispherical substrate. These challenges were overcome through the use of closed-loop weld pool control, height monitoring, a strong understanding of build parameters, and unique process planning strategies. The near-net shape LENS part was completed with annealing and conventional machining to produce the complex components in a reduced timeframe.

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