Deep Reach Wire Based Inner Diameter Laser Cladding Capability Navy SBIR FY2012.1 Sol No.: Navy SBIR FY2012.1 Topic No.: N121-047 Topic Title: Deep Reach Wire Based Inner Diameter Laser Cladding Capability Proposal No.: N121-047-1042 Firm: POM Group, Inc. 2350 Pontiac Road Auburn Hills, Michigan 48326 Contact: Bhaskar Dutta Phone: (248) 409-7900 Web Site: www.pomgroup.com Abstract: In the Navy, severe seawater corrosion is the main cause for damage and failure of high value components in submarine or other vessel components, and weapon systems. While replacement of these components are expensive and time consuming, in-situ repair is challenging due to the geometry constraints by their small bore sizes. Long lead-times and high costs of procuring, inventorying and transporting replacement parts has resulted in a reduction of equipment readiness rates, while DoD operation and support costs have increased. Insertion of additive manufacturing technologies, such as Direct Metal Deposition (DMD) offers an excellent solution to this challenging problem. With its close loop process control and 5-axis deposition capability, DMD allows finer microstructure, shorter heat affected zone, and better mechanical strength of refurbished parts as compared to other open loop processes. This proposal aims to design and develop a new type of wire-based laser cladding nozzle that will be able to meet all the challenges currently facing. Based on POM's extensive past experience in laser cladding nozzle and machine design, a compact nozzle will be designed with quick disconnects for easy and fast mounting/dismounting capability, while a telescopic hardware design will allow deep reach within a short space. Benefits: Main thrust for the application of the current product will be in-situ repair applications for the DoD industry. Over past five years, POM has been closely working with US Navy (ONR & NUWC) through Focus: Hope, a prime contractor on repair, reconfiguration, and restoration of Navy parts using DMD process. Repair process on several parts has been successfully demonstrated, and currently, the parts are under certification process. POM's goal will be to leverage out of this success story, and enhance existing DoD repair capability by usage of the new ID nozzle proposed in this effort. Current repair processes are limited due to their dependence on usage of metal powder as filler material. Metal powders cause a containment challenge, and consequently contaminations risk to other components on-board the naval vessels. This inherently limits their usage for in-situ repairs, and requires the damaged part to be un-installed and replaced, while the repair takes place off-shore in ship yards, causing delay and soaring repair cost. Usage of a wire based repair process offers an excellent solution to this challenging problem. Metal wires avoid risk of contamination, and in-situ repair is instantly viable. In the case of Navy, submarine components will tremendously benefit from such an in-situ repair technology, however, other shipboard components will also be beneficiary of this technology. Similar applications exist across the DoD agencies, such as the Army, Air Force, and Marines. All the agencies have vehicles or weapons systems with components that undergo significant wear and tear, erosion and corrosion due to aggressive service environment, and require constant maintenance. While DoD is actively pursuing field deployable repair technologies, there has been limited effort on in-situ repair technologies. This stems from the above-mentioned challenges. Once the current technology is fully developed, and performance is successfully benchmarked, its usage is expected to be wide spread. POM is already working with agencies such as, Anniston Army Depot, and Tinker Air Force Base, and defense contractors such as, Northrop Grumman Corp., Boeing, Pratt & Whitney, and Aerojet. New, small bore ID cladding technology will be an useful tool to extend application of DMD technology to many more components that are not amenable today. Return