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The laser-assisted double-wire welding process with nontransferred arc (LDNA) is used for Additive Manufacturing of big structures or for large area cladding of components. The process is characterized by a high deposition rate of 5–20 kg/h. For the mobile application of the process using a robot with a maximum payload of 6 kg, the goal was to develop a compact processing head weighing a maximum of 5 kg. A key element is the beam guidance system, which consists of a single-axis galvanometer scanner that must be located in an encapsulated housing due to process emissions. The welding torches, which form the second important element, are brought into position by a torch holder that is adjustable relative to the laser beam. This paper describes the development of a compact processing head for the mobile application of the LDNA process with a robot and the subsequent testing.

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Development and Evaluation of a Compact Processing Head for Additive Manufacturing with Laser-Assisted Double-Wire Welding with Nontransferred Arc

  • 会议论文

  • 发表日期：

    2025年

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  • Kai Biester,
  • Marius Bernaschek,
  • Marius Lammers,
  • Alexander Barroi,
  • Sörn Ocylok,
  • Volker Krause,
  • Ulrich Prank,
  • Florian Wagner,
  • Richard Banaschik,
  • Nick Schwarz,
  • Jörg Hermsdorf,
  • Stefan Kaierle

摘要

The laser-assisted double-wire welding process with nontransferred arc (LDNA) is used for Additive Manufacturing of big structures or for large area cladding of components. The process is characterized by a high deposition rate of 5–20 kg/h. For the mobile application of the process using a robot with a maximum payload of 6 kg, the goal was to develop a compact processing head weighing a maximum of 5 kg. A key element is the beam guidance system, which consists of a single-axis galvanometer scanner that must be located in an encapsulated housing due to process emissions. The welding torches, which form the second important element, are brought into position by a torch holder that is adjustable relative to the laser beam. This paper describes the development of a compact processing head for the mobile application of the LDNA process with a robot and the subsequent testing.