Ultrasonic Vibration-Assisted Laser Assisted Net Shaping of Inconel 718 Parts

Ultrasonic Vibration-Assisted Laser Assisted Net Shaping of Inconel 718 Parts
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Ultrasonic Vibration-Assisted Laser Assisted Net Shaping of Inconel 718 Parts
Introduction
As an extensively utilized preservative engineering technology, laser assisted net shaping (LENS) is at this
moment portioning as one of the significant technologies in the undeviating engineering or refurbishing of
metal portions. Beginning from a computer-aided design (CAD) compact file, the LENS development yields
portions sheet by sheet with the heat involvement of a dynamic laser. Paralleled to outmoded superficial
treatment progressions, LENS has an advanced overhaul efficacy, fewer post-dispensation, a sophisticated
refrigeration rate, and a lesser heat-affected region, hence accomplishing improved machine-driven
performances after installation progressions. Being dissimilar from other preservative engineering processes,
LENS can engineer near-net-shaped archetypes, great superiority metal parts, and even exceptional tooling for
instillation molds. Of late, LENS has been effectively practical in the unswerving manufacture of multifaceted
mechanical components, functionally sorted coverings, great quality auxiliary constituents’ repair, and superior
industries such as aviation, security among others.
As it was established in 1997, LENS has displayed a countless prospective to transform metal parts production
and it has fascinated extra and supplementary consideration in both college circles and other productions. In the
last eras, the study emphasis has remained the optimization of machine-driven possessions and microstructures
of modules invented by LENS and updraft modeling and regulation over the complete residue deposition
process. These inquiries have delivered an indistinct consideration of the features of LENS and have stimulated
this machinery as a key phase en route for authentic manufacturing uses.
Laser Assisted Net Shaping (LANS) is a type of laser assisted powder deposition where powdered metal is
delivered through a nozzle and melted by a laser beam through the process of direct metal rapid prototyping [1-
2].The Laser Assisted Net Shaping has various advantages in the fabrications and repairing of metals including
its high efficiency in the utilization of the powder, high efficiency in part building and production of metal parts
with very high quality [3].
Inconel 718 is a super alloy of nickel as the main component, hardened through precipitation, normally applied
in the manufacture or repair of aircraft engine turbines. According to Zhong [4]. Inconel 718 has some of the
best preferred qualities including its resistance to corrosion, high fatigue strength and its resistance to oxidation
at higher temperatures. However, this process is faced with a number of problems such the development of
cracks and porosity of the fabricated elements .Ultrasonic vibration is normally used in assisting the laser
assisted net shaping for the reduction of such challenges and improve the engineering properties of the
fabricated elements [5].

Laser engineered net shaping (LENS) has developed an auspicious technology in uninterrupted manufacturing
or revamping of high-performance metal portions. Research on LENS developing of Inconel 718 (IN718)
fragments have been piloted for probable uses in the plane turbine constituent engineering or mending.
Assembly imperfections, such as apertures and dissimilar microstructures, are unavoidably prompted in the
parts, distressing part potentials and automated properties. As a result, it is essential to inspect a high-efficiency
LENS progression for the first-rate IN718 part assembly. Ultrasonic vibration has been employed into
innumerable melting material solidification methods for section routine enhancements. Nevertheless, there is a
deficiency of revisions on the consumption of ultrasonic vibration in LENS development for IN718 fragment
engineering. Investigational soundings are steered to study the special effects of ultrasonic vibration on
microstructures and automated possessions of LENS-fabricated fragments underneath dual stages of laser
power. The results in various research done displayed that ultrasonic vibration may perhaps lessen the average
porosity to 0.1%, improve the microstructure with a mean grain size of 5 micrometer, and portion the
unfavorable Laves advanced phase into small subdivisions in a undeviating dissemination, thus improving yield
strength, final tensile strength (UTS), toughness, and wear resistance.
However, the whole laser engineered process and the application of ultrasonic vibration consumes a lot of
energy and therefore there is need for the analysis of the energy consumption of the process [6-7-8] .This paper
therefore provides the data and statistical analysis of the data on the energy consumption of the process.
Parameters and the Sample Population
According to Frost [9], the analysis of the population is always important before the beginning of any study in
order to meet the objectives of an analysis or study. It is important to note that a population may include the
theoretical constructs of an experiment which can be potentially infinite in terms of size. Subpopulations are
sometimes brought on board to enhance the analysis. The parameters are values that are used to describe the
population and the real values are always unknown. The most common parameters in statistics include the mean
and the standard deviations which are based on the size population sample.
In this statistical study, the characteristics or variables including laser power, the rate of powder feed and the
rate of scanning in relation to the energy consumption is analyzed. The values of the variables are varied with
the laser power (Watts) ranging from 275 to 350; speed of scanning in mm/s ranging from 6.0 to 13 and the rate
of powder feed in rpm ranging from 2.0 to 4.0.
Constant variables such as the thickness of the layers, rate of gas flow and number of layers are also considered.
In this analysis the gas flow rates, layer thickness and number of layers of 6 L/min .0.43mm and 4 respectively.

Data Collection
Data for use in the statistical analysis is categorized into primary and secondary data. The raw data obtained
from the field through various data collection methods such as laboratory experiments and observations are the
primary dats. The secondary data includes the already obtained and recorded data by different researchers. This
statistical analysis on the energy consumption of the ultrasonic vibration assisted LANS with the 718 parts
includes the use of both primary and secondary data.
The system for data collection for this system included the determination of the current and the voltage for the
supplied power. The collected data are recorded and tabulated with various variables.
The Measurement of Energy Consumption
Having the input power ,P; voltage, U; time, T; total time, Tt; idling time Ti; laser current Il; power feeder
current If; control system current Is; UV current Iuv; block area, S and block height, h ,then consumed energy
is expressed as:
E= PT
V = U [ I l (T t −Ti )+ ( If + I s + Iuv ) Tt ]
Sxh ... ... ... ... ... .. ... ... ... .( I )