The Generation of Functional Surfaces using Laser-based Hybrid Manufacturing

Hybrid manufacturing using Direct Energy Deposition is a technique which has been gaining industrial interest with a number of major machine tool manufacturers offering machines with the capability for both subtractive and additive manufacturing. While the economic justification for utilising a hybrid machine tool for original part manufacturing is still debatable and is dependent on a number of factors, the attraction of hybrid technologies for remanufactured parts is more straightforward. Examples of parts which could be remanufactured using hybrid technology include automotive camshafts, valves and dies.

However, a significant challenge exists in optimising the process to ensure better productivity and throughput. To achieve this, a fundamental understanding of the material deposition process is needed which, coupled with the process parameters, will result in the ideal deposition thickness as well as the desired surface finish. If the two outputs of thickness and surface finish are better understood then this could negate the need for a final finishing process thus reducing the cycle time.

The aim of this project is to acquire a better understanding of the hybrid manufacturing process and how this can influence the types of surfaces generated on a workpiece and how it performs.
The objectives are as follows:
1. To develop a fundamental understanding and model of the laser-material interaction process and how it relates to the process parameters (jointly with KU Leuven)
2. To apply the process knowledge to generate parts with modified surfaces which exhibit properties such as enhanced wettability, lubricant retention, reduced susceptibility to corrosion etc.
3. To develop a surface characterisation toolbox which can both quantify the surface properties and predict its performance (jointly with KU Leuven)
4. To demonstrate the process on a number of components representing various sectors including aerospace, marine and oil & gas.