Improvement of the laser direct metal deposition process in 5-axis configuration

The implementation of the continuous 5-axis configuration can extend the limits of the Laser Direct Metal Deposition (LDMD) processes, especially when the complexity of the parts to be built is growing. In order to follow the profile of a part, we use the orientation of its growth axis. Although 5-axis machining is well known nowadays, LDMD processes require a specific optimization that depends on many parameters. Unlike conventional machining, it has to be noted that the speed variation tool tip affects the stability of deposition. Thus, we have to smooth trajectories in order to provide fluid movements and also to ensure the stability of deposition. This article describes the method and results in the optimization of trajectories to build metallic parts with freeform. Optical sensors have been implemented in the focusing unit in order to follow the variations of the laser-powder-substrate interaction and also to detect the process instabilities. Thanks to the right use of a new and large 5 axis machine and specific setting trajectories, manufacturing parts in 5-axis, with no concession on the construction rate has been possible.