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Deep Reach Wire Based Inner Diameter Laser Cladding Capability
Navy SBIR 2012.1 - Topic N121-047 NAVSEA - Mr. Dean Putnam - dean.r.putnam@navy.mil Opens: December 12, 2011 - Closes: January 11, 2012 N121-047 TITLE: Deep Reach Wire Based Inner Diameter Laser Cladding Capability TECHNOLOGY AREAS: Materials/Processes ACQUISITION PROGRAM: PMS 392, Strategic and Attack Submarine Program Office OBJECTIVE: Research and develop the components/process to create a Deep Reach Wire-Based Inner Diameter (ID) Laser Cladding Capability to improve material refurbishment characteristics and reduce repair time/costs for small bore shipboard components. DESCRIPTION: There are many high-value fleet system components having corrosion and/or wear damage inside small cylindrical bore shapes that cannot be repaired ship-board with existing commercially available laser cladding repair systems due to geometric constraints. There are industrial laser cladding systems that can perform these types of repairs in a shop environment using "powder-based" filler material; but there are no commercially available systems that use "wire-based" fillers. The powder-based systems create a containment and contamination issue that presently restricts their use in the shop environment. There are unique challenges and unknowns associated with wire cladding inside a narrow bore that must be adequately researched to support a product solution. The melt pool characteristics, material addition/delivery, laser beam reflections, heat dissipation, laser power, heat affected zone (HAZ), gas coverage/type, clad deposit characteristics, and grain structure are just some of the elements that must be addressed. This topic is seeking research and development of an advanced repair capability to address current deficiency. Potential repair applications for a Deep Reach Wire-Based ID Laser Cladding capability are ship and submarine valve bodies, pump and motor housings, hydraulic components, hull penetrations, and dampening system components. A typical architecture for laser cladding includes the following high-level subsystems, however the scope of this topic only pertains to the last element, "Laser Processing Work-Head." - Laser system: Includes the laser, chiller, and fiber optic beam delivery cable. - Laser Processing Work-Head: An optics assembly that processes the laser beam to melt the substrate and filler material at the repair area creating a full metallurgical bond. The work-head shall have a method for mounting to the positioning system (i.e. robot), be able to connect to a fiber optic beam delivery cable, have real-time video feed for wire alignment and process monitoring, provide gas coverage routing, connect to a commercially available wire-feed system and have a robust mechanism for wire-alignment positioning. For the purposes of this topic, the Laser Processing Head will have a wire filler material and have the ability to repair inside cylindrical bores. The scope of this topic is the necessary development of the Laser Processing Work-Head, as described above, with deep reach cladding capability. The Deep Reach Wire-Based [small] ID Laser Cladding Repair Capability shall be capable of depositing metal-based wire filler material on metal-based substrate inside cylindrical bores with targeted dimensions of 4 inches or less in diameter and 18 inches deep. Development of an innovative method for performing the wire alignment/setup to the melt pool and offset distance to the work piece shall also be included in the effort. The head must be portable, which permits removal, transport, and reconnection with the Laser Cladding Repair System, either in a shop environment or onboard a submarine. A successful effort will result in an industrial-hardened Laser Processing Work-Head with deep reach wire cladding capability ready for delivery to Navy maintenance organizations for use with existing laser processing equipment. In addition to the hardware development effort, experiments will be performed to optimize deposition parameters for a select group of commonly used materials. PHASE I: Develop concepts for a Laser Processing Work-Head that will provide a Deep Reach Wire-Based [small] ID Laser Cladding Repair Capability and meet the requirements described above. Demonstrate the feasibility of the concepts to provide the capability and the feasibility of developing the technology to achieve the capability. Provide data on expected repairable geometrical shapes, material types, deposition rates, portability, and interface requirements. Document optimum parameters, approach, tradeoffs, benefits, and risks. Prepare a Phase II development plan with performance goals and key developmental milestones. PHASE II: Based on the results of Phase I and the Phase II development plan, develop a working prototype of the selected concept. Evaluate the prototype using expected geometries (bores) constructed of Navy common materials, and develop a set of optimum repair parameters. Demonstrate that the prototype can interface with a typical laser cladding robotic system to repair mockups of representative Navy components in a simulated shipyard operating environment. Demonstrate the portability of the system by interfacing with a Navy Laser Cladding System and then performing mockup repairs in a simulated shipyard operating environment. Based on evaluation results, determine the refinements that would be needed to refine the prototype into an industrially hardened portable unit. PHASE III: If Phase II is successful, the small business will be expected to support the Navy in transitioning the technology to Navy use should a Phase III award be made. The small business will finalize the deep reach solution, including any refinements and lessons learned in Phase II. The small business will conduct testing necessary to qualify the Laser Processing Work-Head for Navy use and applications. PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The technology/components developed as part of this effort has the potential to benefit the commercial sector by expanding the capability of laser based repair technology. Business areas that could benefit from a Deep Reach Wire-Based ID Laser Cladding system would include the oil, mining, coal, power generation, and the automotive industries. These industries have similar needs as the Navy for improved repair metal deposition processes to recover high-value components. Other DoD agencies including the Air Force and Army, along with other federal agencies such as the Department of Energy (DOE) could also benefit from the advancement of this technology. REFERENCES: 2. Bergan, Patrick, Implementation of Laser Repair for Navy Aluminum Components; Diminishing Manufacturing Sources and Material Shortages (DMSMS) Conf Aug 2000. <http://smaplab.ri.uah.edu/Smaptest/Conferences/dmsms2K/papers/decamp.pdf>, 3. Malin, Valdemar, Richard N. Johnson, and Federico M. Sciammarella. Laser Cladding Refurbishes Navy Ship Components. Alion Science and Technology Corporation, DuPage Manufacturing Research Center St Charles, IL. AMPTIAC Quarterly Volume 8, number 3, 2004 KEYWORDS: Laser cladding deposition; Robotics; laser processing work-head; deep reach small bore repair; wire-based laser cladding; powder-based deposition systems
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