Laser metal deposition (LMD)

BLS advantages with laser metal deposition

Laser Metal Deposition (LMD) offers freedom of design, economic process speed and extraordinary flexibility in the use of materials. The process can precisely apply thin layers from 30 µm to 1.5 mm thick. It enables components to be gently enhanced with a valuable, functional layer or repaired cost-effectively at specific points. Automated laser guidance ensures the highest quality and precision.

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What is laser metal deposition?

Laser metal deposition – often also called laser metal deposition (LMD), direct metal deposition (DMD) or direct energy deposition (DED) – is a generative production method for various metals. While a laser melts the surface of a component in a targeted manner, a metallic filler material in the form of metallic powder is introduced at the same time. This material forms a form-fit, firmly welded layer of 0.01 to 1.5 mm per application. Complex geometries and structures can be applied by applying several layers in succession.

The process therefore enables 3D laser printing of metal. Compared to the alternative metallic 3D printing process – laser metal fusion (LMF) – the processing of the component takes place in free space. Laser metal deposition therefore offers more freedom and flexibility in contrast to LMF, where the process must be carried out in the housing of a 3D printer. Laser metal deposition (LMD) is also suitable for large series due to the shorter cycle times and high degree of automation.

Success factors in laser metal deposition

Various materials can be deposited using laser cladding. Currently, laser cladding of copper, laser cladding of nickel or laser cladding of cobalt are particularly popular applications. Laser metal deposition of aluminium and laser metal deposition of titanium are also standard in laser material processing.

In addition, laser metal deposition (LMD) can be used to switch between different materials or to apply a special combination of materials that would otherwise not exist. For example, a component with an alloy of nickel or iron can be refined with tungsten carbide powder for particularly high wear protection. The process is therefore ideal for all applications in which an expensive material is only to be used in the critical areas of a component for economic reasons. This enables a highly economical use of valuable raw materials.

Verschlissene Oberflächen: Gezieltes Aufbringen neuer Materialschichten in der gewünschten Stärke ermöglicht die Reparatur von Lager- bzw. Dichtflächen sowie abgenutzten Wellen.
Fehlstellen: Löcher, Risse und ähnliche Defekte werden zuverlässig aufgefüllt und geschlossen.
Abgenutzte oder defekte Konturen: Bauteilkonturen lassen sich durch gezielten Aufbau neuer Materialschichten nacharbeiten und damit präzise wiederherstellen.
Schwachstellen: Das gezielte Auftragen zusätzlicher Materialschichten verstärkt Bauteile an Schwachstellen.

Des Weiteren ermöglicht Laserauftragschweißen das Aufbringen von Schutzschichten, um Korrosion und Verschleiß vorzubeugen.

Laser Metal Deposition Procedures

The LMD process is versatile. Besides the EHLA process (“Extreme High Speed Laser Material Deposition”), BLS can also use laser cladding for laser coating or laser repair. In addition, laser metal deposition 3D laser print various shapes or join components with large gaps as a generative manufacturing.

EHLA procedure

Extremely fast application (up to 250cm²/min) by heating the powder already before the melting bath & thus melting faster; allows thin layers of 30-300 µm thickness

Laser repair

Fast, efficient and simple repair of expensive components that could otherwise only be procured new at high cost or with long delivery times

Assemble

Joining of components not suitable for laser welding; includes welding of large gaps or joining of dissimilar materials

Laser coating

Targeted upgrading of a component via the application of a thin, valuable material layer to protect against wear or corrosion

Over 35 years of experience and the trust of
more than 500 customers speak for us.

With extensive laser experience, BLS supports customers as a contract manufacturer from parameter determination / basic development through prototype production to series production. High-performance machinery and different types of lasers and systems enable an optimized overall product. The quality management system and exchanges with leading research institutions ensure quality at the highest level on a permanent basis.

Do you have any questions about what BLS Lasertechnology GmbH has to offer?

BLS Laser Metal Deposition Offering

BLS Lasertechnology GmbH is an expert for laser metal deposition in Germany and offers a wide range of services. BLS already helps from the beginning of the product development process with the conception to ensure the best possible processing of the components.

Support in the design of the component for an optimal cladding result
Design and manufacture of individual fixtures and clamping systems
Cleaning of the parts before processing with an in-house industrial cleaning plant
Laser metal deposition from prototypes (sample production) to serial production
(Partial) automation of loading and unloading for large production batches

Determination of optimal laser types and correct powder selection, parameter determination and application development
Possibility to manually tack and e.g. align components before the deposition welding process
Heating: thermal with industrial furnace (inner dimensions: 1000 x 1000 x 1000mm) or inductive with generator
Laser Metal Deposition according to technical drawing and coordination
Testing of the applied material layer in BLS internal measurement laboratory

Laser metal deposition expertise

In 3D welding (additive laser cladding), a variety of materials can be applied to a metallic component. Different materials can be applied alternately or simultaneously in a mixing ratio using several conveyor units and conveyor gases. This allows new, special alloys to be developed depending on the required function. The material layers can be applied in any shape, allowing large-scale changes to geometries.