LASFORM TECHNOLOGY

Manufacturer AEROMET CORPORATIONS (Subsidiary of MTS), USA

Year 1997
Model Name AeroMets Lasform Machine

Process

The process is described as follows:

The AeroMet laser-forming process starts with a CAD representation of the part. This is
then translated via proprietary software to generate trajectory paths for the laser-
forming system. These paths are transmitted as machine instructions to the laserforming
system.

The focused laser beam traces out the structural shape pattern of the desired part by
moving the titanium target plate beneath the beam in the approximate xy trajectories.

Titanium pre-alloyed powder is introduced into the molten metal head and provides for
the build-up of the desired shape as the molten spot is traversed over a target plate in
the desired pattern.

The 3D structure is fabricated by repeating the pattern, layer by layer over the desired
geometry and indexing the focal point one layer up for the repeating pattern. This layer-
by-layer registry with metallurgical integrity between layers generates the desired
integral ribbed structure called a machining pre-form. Post-processes include heat
treatment, machining and inspection.

*Schematic diagram
 *Equipment and Lasform machine

Principle

The Lasform process uses gas atomized and hydridedehydride titanium alloy powders
introduced into the focus region of the CO2 laser beam.

The focus region is shifted in the XY plane as determined by the CAD slice. This is
achieved by driving a numerical controlled manipulator to reproduce the desired shape.

A solid titanium deposit layer remains and the process is repeated for the next layer in
the Z direction. The new layer is also fused with the previous one, building layer upon
layer until the part is completed.

The process is carried out in an argon-filled environment.The production of high

quality titanium shapes via laser direct metal deposition requires the integration of
several technologies.

These include high power laser beam generation and delivery, metal powder handling,
robotics, process sensing and control, and environmental controls. AeroMet has been
able to integrate these technologies and offer the Lasform on a commercial basis.

Application

Titanium structural components are exclusively manufactured for aircraft applications

The Lasform process can be applied successfully in the manufacturing of integrally

reinforced ribbed structural components for advanced aircraft

Using the Lasform process, the desired geometry can be obtained simply by building the
desired near net shape structure from fused titanium (alloy) powder. Applications in
alloy systems other than titanium are also being identified
 For example, the forging industry has a need to produce relatively large molds and dies
quickly and inexpensively directly out of metal

Todays modern fighter aircraft contain a significant number of structural components

made from hi-tech aerospace titanium alloys such as Ti-6A1-4V, Ti-6Al-2Sn-4Zr-2Mo-
0.8Si, Ti-6Al-2Sn-4Zr-6Mo, Ti-l0V-2Fe-3Al and Ti-15V-3Cr-3Al-3Sn

Because of loading requirements and size and weight constraints, it is often desirable to
make these components monolithic. In order to do so, it is necessary to either cast them
as single components or to machine them out of large titanium billet

*Lasform components

Advantages

High quality titanium parts

Very large parts
Cost and time savings
Flexibility

Disadvantages

Very large physical unit size

Variety of material

Limitations

Not all components and materials are amenable to the Lasform process. Many parts are too
complex and beyond the current capabilities of the technology. Also, components made from
less exotic alloys can be produced more cost effectively using conventional manufacturing
processes. Lastly, a significant portion of the hi-tech aerospace alloys are considered un-
weldable.