www.dmgmori.com Intelligently combined: Laser metal deposition & milling LASERTEC 65 3D Laser metal deposition & milling DMG MORI machines with integrated LASERTEC technology Additive manufacturing for quality finished parts LASERTEC LASERTEC 65 3D forr quality qualiity finished parts partts Laser L aser me metal etall dep deposition posiition with w ith integrated ccapability. apa ability. SAUER LASERTEC, a subsidiary y of DMG MORI SEI SEIKI E KI AG, has iintegrated nteg nt egra r te ra ted d for the first time m , a la llaser ser build-up method in 5-axiss high-tech se h gh-tech mi hi ill lling mach hiness for for o iimpressive mpressive mp time, milling machines fflexibility fl exibility and precision. Instead of using a powder bed, metal dep epos osittio ion is ffacilitated a ilittated ac d via a powde er nozz zzle for o deposition powder nozzle u tto up o 20x faster complete machining of almost any ma mate t ri te rial al witho out a p ro oce c ss cchamber. hamb mb berr. material without process In addition, add d ition, overhanging con onto t urs can be produced without with houtt any y support supp su ppor ortt structures. stt uct stru ctur ures es. contours T he combination comb mbination of additive manufacturing m nufacturing and conv ma n en nv e tional milling on one one machine e The conventional trul uly y opens endless application and geometry possibilities, including cost-effective truly produc cti tion o of large parts. production Flex exib ble l sswitching w tc wi tchi h ng between laser and milling operations allows direct ma achinin ng o Flexible machining off part segments before th the ar area eas be beco come ina nacc cces essi sibl b e due to interference with th subse seq quently areas become inaccessible subsequently deposited component geometry. It I is the inte tell llig igen entt co comb mbin inat atio ion of a dditiv dd ive manufacturing intelligent combination additive and subtractive precision machining that makes this poss s ib ible le. possible. laser metal deposition milling Highlights Materials + Flexible additive manufacturing combined with subtractive precision milling + Easy switching between laser and milling operations for direct machining of part segments not otherwise accessible on a finished workpiece + Laser metal deposition via powder nozzle: 20x faster versus laser sintering in a powder bed + Complete parts production + Stainless steel + Tool steel + Aluminum and aluminum alloys + Cobalt chromium molybdenum alloys + Bronze alloys + Precious metal alloys + Nickel-based alloys + 3D geometries with undercuts + Copper alloys + Turbine and mold parts repairs, wear-resistant coating production + Stellite Operating principle – Laser metal deposition Process direction Powder Laser beam Shield/carrier gas Melting pool Deposited material Deposition area Workpiece Metal powder is applied in layers to a base material and fused together while coaxial shield gas prevents oxidation during the build-up process. A high-strength fusionbonded joint forms with the substrate that, once cooled, can be machined. Target markets Additive manufacturing with finished part quality for production, repair, and coating. 05 Complete parts manufacturing Repair + Prototypes + Tool and mold part repairs + Small series + Inconel turbine component repair, including blades and casings + Large parts + Integral parts + Lightweight components + Complex parts with undercuts LASERTEC 65 3D highlights + MILL + LASER: Full-fledged 5-axis milling machine from DECKEL MAHO with a stable monoBLOCK® design; flexibly integrated laser head via an HSK interface + Complete machining with fully automatic switching between milling and laser operations + Large work area for workpieces up to ø 25.6 in., 14.2 in. high and weighing max. 2,204.6 lbs. + Accessibility and ergonomics: 56.3 in. door opening, optimal front access + Compact 80.7 ft.2 footprint Coatings Partial or complete coatings (technical and wear resistant): 1) Mold making 2) Off shore 3) Mechanical engineering 4) Medical technology Turbine casing Material: Stainless steel Laser metal deposition: 230 min. Milling: 76 min. 3D 3 D component component manufacturing manufaccturing process: process: laser metal deposition 1: Basic sicc bu build ild-up -up u of the casing ring build-up milling 2: 90° swivel – production of the flange 3: 90° swivel – milling of the plane surface and outer contour 4: Flange drilling laser metal deposition 5: Continued cylinder build-up 6: Transition section build-up 7: Conical funnel build-up laser metal deposition 9: Build up of the 12 connectors 8: Production of the second flange milling 10: Milling of the 12 connectors 11: Milling of the flange and inner contour 12: Milling of the inner holes Additive manufacturing with a powder nozzle // Benefits + Complete machining (of almost all materials) without a process chamber for up to 20x faster production versus laser sintering in a powder bed + 0.004 in. to 0.2 in. wall thickness (depending on laser and nozzle geometry) + Overhanging contours without support geometry (e.g. flanges, cones) + Flexible switching between laser and milling operations for direct machining of part segments previously not accessible on a finished workpiece + 56.3 in. door opening, optimal front access + Integrated switch mechanism in the work area + Laser source: 2 kW laser diode comes standard (selectable by application) + Best surface quality & component precision + Components with finished part quality + Automatic switching between laser and milling operations + Compact 80.7 ft.2 footprint Exhibitions 2014: September 08 – 13, 2014: imts, Chicago, IL, USA September 16 – 20, 2014: amb, Stuttgart, Germany October 30 – November 04, 2014: jimtof, Tokyo, Japan November 25 – 28, 2014: euromold, Frankfurt, Germany DMG MORI USA 2400 Huntington Blvd., Hoffman Estates, IL 60192 Tel.: (847) 593-5400, Fax: (847) 593-5433 [email protected], www.dmgmori.com MONTFORT + Milling between laser operations Technical update rights reserved. The machines depicted here may include some options, equipment and CNC alternatives. + Large work area for workpieces with up to ø 25.6 in., 14.2 in. lengths, and weighing max. 2,204.6 lbs. + Laser head integrated via HSK interface on the spindle 5-axis milling Subject to modification. + Full-fledged 5-axis milling machine with a stable monoBLOCK® design 3D laser metal deposition FLY_D6170/0114US_NB D6139/0314AD6 Highly dynamic machine ADVERTISING Unique hybrid solution with many special features.
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