Wire Laser Metal Deposition Additive Manufacturing of Duplex Stainless Steel Components-Development of a Systematic Methodology.

A systematic four-stage methodology was developed and applied to the Laser Metal Deposition with Wire (LMDw) of a duplex stainless steel (DSS) cylinder > 20 kg. In the four stages, single-bead passes, a single-bead wall, a block, and finally a cylinder were produced. This stepwise approach allowed the development of LMDw process parameters and control systems while the volume of deposited material and the geometrical complexity of components increased. The as-deposited microstructure was inhomogeneous and repetitive, consisting of highly ferritic regions with nitrides and regions with high fractions of austenite. However, there were no cracks or lack of fusion defects; there were only some small pores, and strength and toughness were comparable to those of the corresponding steel grade. A heat treatment for 1 h at 1100 °C was performed to homogenize the microstructure, remove nitrides, and balance the ferrite and austenite fractions compensating for nitrogen loss occurring during LMDw. The heat treatment increased toughness and ductility and decreased strength, but these still matched steel properties. It was concluded that implementing a systematic methodology with a stepwise increase in the deposited volume and geometrical complexity is a cost-effective way of developing additive manufacturing procedures for the production of significantly sized metallic components.

National Inventory of Landscapes in Sweden (NILS)--scope, design, and experiences from establishing a multiscale biodiversity monitoring system.

The landscape-level and multiscale biodiversity monitoring program National Inventory of Landscapes in Sweden (NILS) was launched in 2003. NILS is conducted as a sample-based stratified inventory that acquires data across several spatial scales, which is accomplished by combining aerial photo interpretation with field inventory. A total of 631 sample units are distributed across the land base of Sweden, of which 20% are surveyed each year. By 2007 NILS completed the first 5-year inventory phase. As the reinventory in the second 5-year phase (2008-2012) proceeds, experiences and insights accumulate and reflections are made on the setup and accomplishment of the monitoring scheme. In this article, the emphasis is placed on background, scope, objectives, design, and experiences of the NILS program. The main objective to collect data for and perform analyses of natural landscape changes, degree of anthropogenic impact, prerequisites for natural biological diversity and ecological processes at landscape scale. Different environmental conditions that can have direct or indirect effects on biological diversity are monitored. The program provides data for national and international policy and offers an infrastructure for other monitoring program and research projects. NILS has attracted significant national and international interest during its relatively short time of existence; the number of stakeholders and cooperation partners steadily increases. This is constructive and strengthens the incentive for the multiscale monitoring approach.

Optical techniques for real-time penetration monitoring for laser welding.

Optical techniques for real-time full-penetration monitoring for Nd:YAG laser welding have been investigated. Coaxial light emission from the keyhole is imaged onto three photodiodes and a camera. We describe the spectral and statistical analyses from photodiode signals, which indicate the presence of a full penetration. Two image processing techniques based on the keyhole shape recognition and the keyhole image intensity profile along the welding path are presented. An intensity ratio parameter is used to determine the extent of opening at the rear of a fully opened keyhole. We show that this parameter clearly interprets a hole in formation or a lack of penetration when welding is performed on workpieces with variable thicknesses at constant laser power.

Closed-loop power and focus control of laser welding for full-penetration monitoring.

We describe a closed-loop control system ensuring full penetration in welding by controlling the focus position and power of a 4-kW Nd:YAG laser. A focus position monitoring system was developed based on the chromatic aberration of the focusing optics. With the laser power control system we can determine the degree of penetration by analyzing the keyhole image intensity profile. We demonstrate performance in bead-on-plate welding of Inconel 718 and titanium. The focus control system maintained a focal position on tilted and nonflat workpieces, and the penetration monitoring technique successfully controlled the laser power to maintain the full-penetration regime in the presence of linear and step changes of thickness. Finally we discuss the performances and the limits of the systems when applied to a realistic complex aerospace component.