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Laser materials processing system technology has become indispensible to the tool and die manufacturing industries and for repairing engines and turbines. The laser build‐up welding process especially is now a standard technology where cost efficient, precisely localized and near net shape repair welds are required. The concept of integrating the modular laser components into standard machine tools makes the technology easily accessible to the user and very efficiently combines build‐up welding and metal‐cutting processes.

Specially designed laser system technology is available as add‐on kits for different machine tools of the end‐users. They can choose from a large variety of laser sources, manufacturing heads, welding material supply as well as process control devices. User‐friendly software guides through the entire process chain. So, optimized laser systems for different cladding and build‐up applications can be installed easily and inexpensively in common turning and milling machines.

The laser integration into machine tools connects efficiently laser and mechanical finish operations. This way, repairs, rapid design changes, and direct manufacturing of parts are available with a high level of accuracy and in very short times. Additionally, exactly specified property profiles can be realized.

The laser application shown here represents a new technical solution of laser integration into machine tools, which offers an efficient complete machining. It allows to quickly switch between milling and laser processing, which simplifies the combination of both processes. The computer numerical controlled process control treats the laser head just like a milling tool. This shortens the machining time and expands the capability of the machine with respect to generating multiple shapes.

Time reduction and quick geometrical changes of complex components and tools are currently the most important demands in product development. The manufacturing process presented in this paper is based on multiple additive and subtractive technologies such as laser cutting, laser welding, direct laser metal deposition and CNC milling. The process chain is similar to layer‐based Rapid Prototyping Techniques. In the first step, the 3D CAD geometry is sliced into layers by a specially developed software. These slices are cut by high speed laser cutting and then joined together. In this way laminated tools or parts are built. To improve surface quality and to increase wear resistance a CNC machining center is used. The system consists of a CNC milling machine, in which a 3 kW Nd:YAG laser, a coaxial powder nozzle and a digitizing system are integrated.

The aim of the paper is to provide an economically viable solution for the blade repair process. There is a continual increase in the repair market, which requires an increased level of specialised technology to reduce the repair cost and to increase productivity of the process.Design/methodology/approach – This paper introduces the aerospace component defects to be repaired. Current repair technologies including building‐up and machining technology are reviewed. Through the analysis of these available technologies, this paper proposes an integrated repair strategy through information integration and processes concentration.Findings – Provides detailed description and discussion for the repair system, including 3D digitising system, repair inspection, reverse engineering‐based polygonal modelling, and adaptive laser cladding and adaptive machining process.Originality/value – This paper describes a 3D non‐contact measurement‐based repair integration system, and provides a solution to create an individual blade‐oriented nominal model to achieve adaptive repair process (laser cladding/machining) and automated inspection.

Additive manufacturing (AM) is a rapidly evolving manufacturing process, which refers to a set of technologies that add materials layer-by-layer to create functional components. AM technologies have received an enormous attention from both academia and industry, and they are being successfully used in various applications, such as rapid prototyping, tooling, direct manufacturing and repair, among others. AM does not necessarily imply building parts, as it also refers to innovation in materials, system and part designs, novel combination of properties and interplay between systems and materials. The most exciting features of AM are related to the development of radically new systems and materials that can be used in advanced products with the aim of reducing costs, manufacturing difficulties, weight, waste and energy consumption. It is essential to develop an advanced production system that assists the user through the process, from the computer-aided design model to functional components. The challenges faced in the research and development and operational phase of producing those parts include requiring the capacity to simulate and observe the building process and, more importantly, being able to introduce the production changes in a real-time fashion. This paper aims to review the role of robotics in various AM technologies to underline its importance, followed by an introduction of a novel and intelligent system for directed energy deposition (DED) technology.

AM presents intrinsic advantages when compared to the conventional processes. Nevertheless, its industrial integration remains as a challenge due to equipment and process complexities. DED technologies are among the most sophisticated concepts that have the potential of transforming the current material processing practices.

The objective of this paper is identifying the fundamental features of an intelligent DED platform, capable of handling the science and operational aspects of the advanced AM applications. Consequently, we introduce and discuss a novel robotic AM system, designed for processing metals and alloys such as aluminium alloys, high-strength steels, stainless steels, titanium alloys, magnesium alloys, nickel-based superalloys and other metallic alloys for various applications. A few demonstrators are presented and briefly discussed, to present the usefulness of the introduced system and underlying concept. The main design objective of the presented intelligent robotic AM system is to implement a design-and-produce strategy. This means that the system should allow the user to focus on the knowledge-based tasks, e.g. the tasks of designing the part, material selection, simulating the deposition process and anticipating the metallurgical properties of the final part, as the rest would be handled automatically.

This paper reviews a few AM technologies, where robotics is a central part of the process, such as vat photopolymerization, material jetting, binder jetting, material extrusion, powder bed fusion, DED and sheet lamination. This paper aims to influence the development of robot-based AM systems for industrial applications such as part production, automotive, medical, aerospace and defence sectors.

The presented intelligent system is an original development that is designed and built by the co-authors J. Norberto Pires, Amin S. Azar and Trayana Tankova.

Reports from the 2004 Automotive Laser Applications Workshop in Plymouth, MI on the keynote presentation given by Klaus Loeffler, Volkswagen's joining specialist. Outlines the extent of Volkswagen's use of laser welding to build cars at both assembly plants in Germany and elsewhere.

The purpose of this paper is to review additive and/or subtractive manufacturing methods for metallic objects and their gradual evolution from prototyping tools to rapid manufacture of actual parts.

Various existing rapid manufacturing (RM) methods have been classified into six groups, namely, CNC machining laminated manufacturing, powder‐bed technologies, deposition technologies, hybrid technologies and rapid casting technologies and discussed in detail. The RM methods have been further classified, based on criteria such as material, raw material form, energy source, etc. The process capabilities springing from these classifications are captured in the form of a table, which acts as a database.

Due to the approximation in RM in exchange for total automation, a variety of multi‐faceted and hybrid approaches has to be adopted. This study helps in choosing the appropriate RM process among these myriad technologies.

This review facilitates identification of appropriate RM process for a given situation and sets the framework for design for RM.

Advanced laser micromachining techniques for a TFT‐LCD (thin film transistor‐liquid crystal display) module have been developed to repair various kinds of defects such as shorts, opens, and degraded TFTs. They have also been designed to analyse failures in the TFT‐LCD. The techniques are as follows: (i) The technique of zapping the excess metal: to repair short defects and/or to isolate the TFT being tested from the adjacent TFTs. This uses a pulse Xe or a Q‐switched YAG laser. (ii) Zapping, followed by the metal deposition technique: to repair open defects and/or to form electrical testing electrodes. This uses a Q‐switched YLF and an Ar ion laser. (iii) The technique of micro‐welding two metal lines separated by an insulating layer: to repair open defects. This uses a Q‐switched YAG laser. (iv) A separation technique utilised on a TFT‐LCD panel adhered with epoxy resin. This uses a pulse Excimer laser. (v) A micro‐annealing technique for a degraded TFT: to recover the TFT characteristics. This uses a Q‐switched YAG laser. Through the study described above, the authors have confirmed that these techniques are highly effective for obtaining TFT‐LCD modules without defects. The yield of TFT‐LCD modules may therefore be expected to improve.