Deep Reach Wire Based Inner Diameter Laser Cladding Capability

In the Navy, severe seawater corrosion is the main cause for damage and failure of high value components in submarine or other vessel components, and weapon systems. While replacement of these components are expensive and time consuming, in-situ repair is challenging due to the geometry constraints by their small bore sizes. Long lead-times and high costs of procuring, inventorying and transporting replacement parts has resulted in a reduction of equipment readiness rates, while DoD operation and support costs have increased. Insertion of additive manufacturing technologies, such as Direct Metal Deposition (DMD) offers an excellent solution to this challenging problem. With its close loop process control and 5-axis deposition capability, DMD allows finer microstructure, shorter heat affected zone, and better mechanical strength of refurbished parts as compared to other open loop processes. This proposal aims to design and develop a new type of wire-based laser cladding nozzle that will be able to meet all the challenges currently facing. Based on POM's extensive past experience in laser cladding nozzle and machine design, a compact nozzle will be designed with quick disconnects for easy and fast mounting/dismounting capability, while a telescopic hardware design will allow deep reach within a short space.