Entering the Next Era of Additive Manufacturing with Wire Laser Additive Manufacturing (WLAM)

Additive manufacturing has exhibited continuous global growth in the field of technological development. Particularly, laser additive manufacturing (LAM) technology, which uses a laser as an energy-carrying beam and a metal powder or wire as raw materials, has become a hotspot in research and industrial applications.

AM PravaH® software has made a huge contribution to the production of high-performance metal-alloy components, with remarkable flexibility and dimensional precision. Among the most significant developments in this field, Wire Laser Additive Manufacturing (WLAM), the technology that enables deposition of dense, microstructurally homogenous objects layer by layer with the uniform material integrity, is the most significant. The metal components produced with the help of AM PravaH® software have better mechanical properties that are mainly defined by improved strength and durability.

With the laser-induced wire melting method, the achieved thermal condition is very much controlled, giving a fine microstructural development and minimizing the usual defects such as porosity and inclusions. These components hence have high tensile strength, fatigue life, and hardness when compared to those produced traditionally. The process is successful in eliminating the typical manufacturing weaknesses, thus resulting in a strong mechanism and structural integrity. 

An in-depth overview of the WLAM module in AM PravaH® software:-

Wire Laser Additive Manufacturing (WLAM) is an advanced process of metal feedstock e.g., metal wire, which is melted selectively by a high-power laser to enable controlled material layering to achieve near-net-shape metal parts, built-up layer by layer. The WLAM module in AM PravaH® enables the user to perform detailed simulations of Wire Laser Directed Energy Deposition process with a focus on analyzing the melt pool dynamics.  

Some of the key parameters of the process are:

• Laser power

• wire feed rate

• Laser Scanning speed

• Wire Radius

• Laser beam shape

• Spot Diameter

• Fresnel Coefficients

These parameters bring significant changes to the thermal profile, the melt pool dynamics and the solidification rates that ultimately influence the microstructural characteristics and mechanical properties of the final part obtained.

The ability to precisely control these parameters enables optimization of layer adhesion, density, and surface finish and therefore Wire Laser Additive Manufacturing is very well suited to the production of complex, high-performance geometries with custom microstructures that are highly desirable in the aerospace, automotive, and other industries that require structurally critical and reliable metal parts.

Laser-Wire Deposition vs. Powder-Based Techniques:

Laser power bed fusion (LPBF) and Wire Laser Additive Manufacturing (WLAM) are the two most differentiated techniques among the other additive manufacturing methods. Each has its strengths, although there are some strong arguments why wire-laser additive manufacturing is usually better than the other in most industrial uses. 

• Efficiency and Speed:- The WLAM module can also be more efficient and faster due to the use of continuous wire feed as raw material, which can result in higher deposition rates than the layer-by-layer method of powder-based techniques. This equates to shorter build duration and increased productivity, and thus it is best suited to the production of large parts or prototypes with a shorter deadline. This higher deposition efficiency is useful in high-scale parts or for the rapid prototyping process, where time is limited and where there is a possibility of working on large surfaces of several meters. 

• Material Waste:- One of the significant advantages of the AM PravaH® wire laser process is its efficient use of raw material. With powder-based systems, a considerable amount of unused powder often gets wasted, or to prevent wastage, it needs to be recycled, which can be time-consuming and costly.

Manufacturing parts with WLAM tends to produce smoother surface finishes with fewer defects, as there is less risk of porosity and other powder-related issues. This can result in fewer post-processing steps, less computational time, and reduced overall production costs.

• Operator Safety and Material Handling:- Handling metal powders comes with inherent risks, including inhalation hazards and the potential for dust explosions. Powder-based systems require stringent safety measures like proper protective gear and ventilation systems and specialized equipment to mitigate these risks. On the other hand, the laser-wire method uses welding wire, which is inherently safer to handle and reduces the need for extensive material handling safety protocols.

• Material: The cost of metal alloy powders can be significantly higher than that of metal wire, primarily due to the manufacturing processes involved in creating fine, uniform metal grains.

However, when compared to traditional subtractive manufacturing methods like CNC machining, which typically results in substantial material waste, additive manufacturing uses only the necessary amount of raw material.

• Applications & Versatility:-Wire laser DED process is versatile and can be applied in various industries. It is particularly useful for repairing parts or applying protective coatings, such as in the defense, aerospace, and oil & gas industries. It is also well-suited for the fabrication of very large-scale parts, which can be challenging with powder-based techniques due to smaller size limitations and stringent time constraints.

• Environmental Impacts: Reduced waste and lower energy consumption associated with  AM PravaH® WLAM module contribute to a smaller environmental footprint than a powder-based solution. With powder requiring a great deal of energy and resources to manufacture and its toxicity to humans, laser powder bed fusion is not considered a sustainable choice.

As industries increasingly focus on sustainability, the ecological benefits of Wire Laser Additive Manufacturing become an essential consideration.

While both wire-laser and powder-based 3D metal printing have their place in manufacturing, the WLAM module of AM PravaH® offers several advantages that can make it a superior choice in many scenarios. Its efficiency, cost-effectiveness, safety, and versatility make it an attractive option for manufacturers looking to optimize their large-scale production processes and compete in the market.