Using Separate Powder Injected Laser Application (SPILA), developed by the DAP Chair and HD Sonderoptiken fuer die Lasertechnik GmbH & Co. KG, allows a tailored adapted approach to individual materials and to improve productivity through direct graded single-layer coatings. Due to the separate adaptive material supply, the powders are individually injected to the process, allowing a tailored Laser-Material interaction. This enables the heating of the powder to be specifically adjusted by process parameters as well as the relative position of the powder feeds to each other. These new possibilities allow the layer composition to be controlled to enable a new dimension in the manufacturing of coatings.
For the processing of two powders, the Triple-Two Powder Nozzle has been developed. Two separate powder gas streams with adjustable relative positions to each other are used to feed the two materials. This allows, for example, a multi-functional graded single-layer coating to be produced. Using a relative shift of the powder focus perpendicular to the laser beam, a two-layer system for combined corrosion and wear protection, which usually requires two passes, can be replaced by a graded single-layer system. However, this innovation can improve the efficiency of processes due to reduced coating times.