Deep Reach Wire Based Inner Diameter Laser Cladding Capability

As the Navy fleet ages there are many system components with small, cylindrical bore shapes with wear and/or corrosion damage which can not realistically be removed for repair. The current repair method most commonly used, brush electroplating, does not last long, requiring frequent repairs. The Navy desires a deep bore wire-based laser cladding capability to accomplish a much longer lasting repair. We propose to develop a portable, robust laser cladding system for repair of small inner diameter components. Included in this effort will be a detailed analysis of the procedures, equipment, and preparations necessary to perform shipboard laser clad repairs in order to show that laser cladding is a feasible, cost efficient repair solution. The laser cladding head design will be based on improving an existing prototype deep bore wire-based laser cladding head. Design improvements will focus primarily on improved process imaging, maintaining a constant head standoff distance, and aligning the filler wire properly in the melt pool of the laser beam.