Additive technology of high-frequency induction-assisted laser wire deposition

A novel high-frequency induction-assisted laser wire deposition (HFLWD) process is proposed, and the feasibility of this method is demonstrated. The effects of the application of an induction coil on the force state of a droplet and the metallurgical bonding between deposited track and substrate are presented. The wire-melting transfer mode with different wire-tip heights was investigated using an infrared thermal-imaging camera. The effects of the process parameters, including the laser power, wire tip height, and wire feeding speed, on the geometrical characteristics of the track (dilution rate, track width, and height) were investigated. The results showed that the application of an induction coil was the dominant factor influencing the uniformity and continuity of the deposited track and ensuring effective bonding between the substrate and deposited track under low laser power. The droplet transfer form can be accurately controlled by changing the height of the front end of the wire. The established prediction model based on the wire-feeding speed accurately predicted the track height.