doi: 10.52899/24141437_2025_01_97
UDK: 62-5

Powder laser cladding as a component of Industry 4.0 machine building systems

Вознесенская А. А., Чкалов Р. В., Киреев А. В., Разносчиков А. С., Кочуев Д. А.
Article language: English
Citation Link: Voznesenskaya AA, Chkalov RV, Kireev AV, Raznoschikov AS, Kochuev DA. Powder laser cladding as a component of Industry 4.0 machine building systems. Transactions of the Saint Petersburg State Marine Technical University. 2025;4(1):97–106. DOI:https://doi.org/10.52899/24141437_2025_01_97

Annotation

This article examines the problem of feeding powder material to laser cladding systems based on state-of-the-art industrial digital transformation standards and presents an overview of existing designs, their advantages and disadvantages. Based on the review, to propose a powder feed system concept that improves the overall cladding performance, control, and automation. The article reviews the main issues related to powder feed system that lead to certain process difficulties in the contemporary industry and increase the amount of subsequent machining in the process. The article reviews approaches to solving the problems of powder feeding to the laser cladding area. The article discusses key aspects related to powder feed systems and provides advice on designing an improved system to feed powder to the laser impact area, bringing powder cladding technology closer to Industry 4.0 systems. Based on the review, the authors propose a powder feed system concept that improves the overall cladding performance, control and automation. Digital process transformation is achieved by the use of a sensor system and reduced inertia of the powder feed process by improving the feed system design and the dosing unit location in the laser cladding powder system. Keywords: additive technologies; powder material; powder supply system; laser cladding; functionally graded materials

Bibliography

1. Kenett RS, Swarz RS, Zonnenshain A, editors. Systems engineering in the fourth industrial revolution: Big data, novel technologies, and modern systems engineering. John Wiley and Sons; 2019. 611 p. doi: 10.1002/9781119513957
2. Wang H, Liu W, Tang Z, et al. Review on adaptive control of laser-directed energy deposition. Opt Eng. 2020;59(7):070901. doi: 10.1117/1.OE.59.7.070901
3. Kladovasilakis N, Charalampous P, Kostavelis I, et al. Impact of metal additive manufacturing parameters on the powder bed fusion and direct energy deposition processes: A comprehensive review. Prog Addit Manuf. 2021;6:349–365. doi: 10.1007/s40964-021-00180-8
4. Ghanavati R, Lannunziata E, Norouzi E, et al. Design and development of SS316L-IN718 functionally graded materials via laser powder bed fusion. Mater Lett. 2023;349:134793. doi: 10.1016/j.matlet.2023.134793
5. Parihar RS, Setti SG, Sahu RK. Recent advances in the manufacturing processes of functionally graded materials: a review. Sci Eng Compos Mater. 2018;25(2):309–336. doi: 10.1515/secm-2015-0395
6. Voznesenskaya AA, Raznoschikov AS, Galkin AF, et al. Distribution of laser radiation in opaque porous media. J Phys Conf Ser. 2022;2316(1):012018. doi: 10.1088/1742-6596/2316/1/012018
7. Herzog D, Seyda V, Wycisk E, Emmelmann C. Additive manufacturing of metals. Acta Materialia. 2016;117:371–392. doi: 10.1016/j.actamat.2016.07.019
8. Demir AG, Kim J, Caltanissetta F, et al. Enabling multi-material gradient structure in laser powder bed fusion. J Mater Process Technol. 2022;301:117439. doi: 10.1016/j.jmatprotec.2021.117439
9. Errico V, Posa P, Fusco A, et al. Intralayer multi-material structure stainless-steel/nickel-superalloy fabricated via laser-powder bed fusion process. Manuf Lett. 2023;35:11–15. doi: 10.1016/j.mfglet.2022.11.004
10. Chernikov AS, Voznesenskaya AA, Davydov NN, et al. Gradient materials formation by laser cladding of powder compositions. J Phys Conf Ser. 2018;1109(1):012062. doi: 10.1088/1742-6596/1109/1/012062
11. Goodarzi DM, Pekkarinen J, Salminen A. Analysis of laser cladding process parameter influence on the clad bead geometry.
Weld World. 2017;61:883–891. doi: 10.1007/s40194-017-0495-0
12. Bax B, Rajput R, Kellet R, Reisacher M. Systematic evaluation of process parameter maps for laser cladding and directed energy deposition. Addit Manuf. 2018;21:487–494. doi: 10.1016/j.addma.2018.04.002
13. Janicki D. Laser cladding of Inconel 625-based composite coatings reinforced by porous chromium carbide particles. Opt Laser Technol. 2017;94:6–14. doi: 10.1016/j.optlastec.2017.03.007 14. Fu F, Zhang Y, Chang G, Dai J. Analysis on the physical mechanism of laser cladding crack and its influence factors. Optik. 2016;127(1):200–202. doi: 10.1016/j.ijleo.2015.10.043
15. Balu P, Leggett P, Hamid S, Kovacevic R. Multi-response optimization of laser-based powder deposition of multi-track single layer hastelloy C-276. Mater Manuf Process. 2013;28(2):173–182. doi: 10.1080/10426914.2012.677908
16. Bridgwater J. Mixing of powders and granular materials by mechanical means — A perspective. Particuology. 2012;10(4):397– 427. doi: 10.1016/j.partic.2012.06.002
17. Toyserkani E, Khajepour A, Corbin S. 3-D finite element modeling of laser cladding by powder injection: effects of laser pulse shaping on the process. Opt Lasers Eng. 2004;41(6):849–867. doi: 10.1016/S0143-8166(03)00063-0
18. Arrizubieta JI, Lamikiz A, Cortina M, et al. Hardness, grainsize and porosity formation prediction on the Laser Metal Deposition of AISI 304 stainless steel. Int J Mach Tools Manuf. 2018;135:53–64. doi: 10.1016/j.ijmachtools.2018.08.004
19. Tan H, Shang W, Zhang F, et al. Process mechanisms based on powder flow spatial distribution in direct metal deposition. J Mater Process Technol. 2018;254:361–372. doi: 10.1016/j.jmatprotec.2017.11.026
20. Arrizubieta JI, Martínez S, Lamikiz A, et al. Instantaneous powder flux regulation system for Laser Metal Deposition. J Manuf Process. 2017;29:242–251. doi: 10.1016/j.jmapro.2017.07.018
21. Jinping Q, Baoshan S, Yanhong F, Hezhi H. Dependence of solids conveying on screw axial vibration in single screw extruders. J Appl Polym Sci. 2006;102(3):2998–3007. doi: 10.1002/app.24658
22. Weerasinghe VM. Laser cladding with pneumatic powder delivery. In: Weerasinghe VM, Steen WM, editors. Applied laser tooling. Dordrecht: Springer Netherlands; 1987. P. 183–211. doi: 10.1007/978-94-009-3569-3
23. Winkler G. Analysing the vibrating conveyor. Int J Mech Sci. 1978;20(9):561–570. doi: 10.1016/0020-7403(78)90014-0
24. Soshi M, Yau C, Kusama R. Development and evaluation of a dynamic powder splitting system for the directed energy deposition (DED) process. CIRP Annals. 2020;69(1):341–344. doi: 10.1016/j.cirp.2020.04.048