WEBINAR:

Additive Manufacturing of Coaxial Nozzles for Laser Cladding

“ A Spare Parts and Digital Inventory Application”

Presented by

SUNEEL KASHYAP
Director-LAYERX
On Demand Manufacturing 25 February 2022
Agenda

• Company Profile

• Problem Statement of the use case

• Reverse Engineering WorkFlow and Production

• Development of AM part – Nozzle

• Spare parts and Digital inventory Application

• Conclusion
YOUR PARTNER FOR ON DEMAND
MANUFACTURING!

Leading Service provider for innovative and customized engineering solutions for different industry verticals in MENA region

DESIGN, REVERSE ENGINEERING AND ADDITIVE MANUFACTURING (3D PRINTING) OF POLYMERS & METALS

We offer a full solution of Product

Design, Reverse Engineering, Rapid
6 Different 3D Printing 40+ Different 3D
Prototyping, Rapid Manufacturing
Technologies in house Printing Materials
using different technologies.
ISO-9001-2015 In Process
The Problem Statement
“Reverse Engineering and Additive Manufacturing of Coaxial Nozzles for Laser Cladding Of corrosion resistance piping systems”

Coaxial Nozzles: Current Problems

• Thin wall section for cooling chanels and low

strength Materials for any manual repairs

• Wire Feeding Nozzles for available for current

laser cladding of corrosion resistance piping
systems are having low strength, Soft material
susceptible to breakage when mounting on the
weld unit

• Highly consumable parts – low On stock

availability and Long lead times and MoQ
Nozzle Reverse Engineering & Production
Project and Additive Manufacturing Work flow

Reverse DFAM and Additive

CAD Design and LPBF and
Engineering and Material Manufacturing Post Processing
3D Modelling Parameters
3D Scanning Selection Process

3D Scanning: we used a Hexagon Portable Measuring Arm with resolution of about 50 Microns.

Reverse Engineering : With the help of reverse engineering softwares we were able to put the cloud points together

CAD Design: Further, with Cad Softwares , we were able to generate and model the 3D CAD

DfAM: Further, to our newer requirements of nozzle length change and improved thickness and flow diameter was performed
for Alsi10mg
LPBF Process: Layer thickness, energy density of laser, build temperature , scanning speed and other parameters were
determined
Additive Process: determine the build rate and build volume and freezing of the orientation and nesting of the part

Post Processing: wire cutting, heat treatment, sand blasting, machining and required threading with optical microscope for
inspection/ tensile Testing for part durability
Development of the AM Part – Nozzle
3D Scanning and Reverse Engineering

Hexagon Portable scanner arm was used to 3D Scan the parts outer details and for the reverse engineering, we used a
destructive method to analyze the conformal cooling ducts inside the nozzle.

Upon confirmation of the sizes of the openings we were able to

successfully introduce the same channels into our Model
 Development of the AM Part – Nozzle
Design Optimization for AM and Analysis

Boundary Conditions
for welding coolant to
flow with a flow rate
of 2-4.5 l/min

Entry and exit of

welding Coolant

IN625 Wire Feeding Nozzles Entry

Development of the AM Part – Nozzle
Additive Manufacturing and Post Processing
Material Selection Alsi10Mg – Aluminum
Material Selection Alsi10Mg – Aluminum For TiG Welding Wire Feeder To have good mechanical properties we have
with copper alloy tips to withstand 200-220 Degree Celsius of TIG tailored Heat treatment process similar to
Welding. conventional T6 – Vickers 104-110
AlSi10Mg is currently the most commonly used aluminium alloy in
LPBF, presumably due to the ease of processing. Aluminium-silicon • Weight of the Original part: 445 grams
alloys are primarily used in castings due to their high melt fluidity • Weight of the New Part: 488 grams
and relatively low shrinkage Tensile Strength Rm [MPa] 405 ± 50 Approx.
• Layer thickness 30 µm
• Volume rate 5.1 mm³/s
• wall thickness 0.4 mm
Spare parts and Digital Inventory

Used Coaxial Nozzles – Scanning and FEA and Flow Analysis for Prototyping for form Additive Manufacturing
Conventional Manufacturing Reverse engineering conformal Cooling and fit functions Alsi10Mg - Aluminum

Comparison of the new spare part Digitized Files – Nozzle Spare part for on demand production

Ref: Crystal Corporation LLC - Dubai

CONCLUSION AND SUMMARY:

Digitization and Reverse Engineering of the Co Axial Nozzles

Industrial Application: Additive Manufacturing of Coaxial Nozzles for Laser Cladding Of corrosion resistance piping
systems

Nozzles play a significant role in the manufacturing of laser cladding machines for several purpose at present era in
laser cladding for different applications. They also play an important role in the cladding techniques and methodology
for a uniform application of the rapid manufacturing of the metal layer in the desired thickness for various industrial
application.

Conventional Manufacturing techniques of these nozzles like sand casting, investments casting, die casting, CNC
machining, etc. can pose severe drawbacks in terms manufacturing process flaws like porosity and contamination
which can quickly lead into damaged parts and higher consumption of the consumables which in-turn affects the
productivity.

Manufacturing the nozzles in a conventional method, consume much time and is not cost-effective. In order to
reproduce and avoid longer supply chains, and physical inventory.

To reduce the spare part supply chain and maintenance of the Nozzles, this project aimed at reverse engineering some
of the existing designs and developing a better and conformal cooling nozzles using CAD software. The Nozzles so
designed is printed using metal Laser bed Fusion additive manufacturing techniques.

Keywords : 3D Printing, Metal Additive Manufacturing, laser bed powder fusion, Rapid Prototyping (RP), Nozzles and
aluminium
Thank you!

Mail:
info@layerx-3d.com
Phone:
+971 471 871 32
Address:
Dubai investment park (DIP)-2 Dubai U.A.E