Process for Laser-Assisted Tool Build and Repair

A tool for forming a shaped product, the tool comprising:

• a support body having a machined surface defining a first portion of a forming surface of the tool;
• and
• a feature supported on the support body adjacent to the machined surface and defining a second portion of the forming surface, the feature comprising a plurality of layers including a top layer formed of a material that is metallurgically incompatible with material of the machined surface of the support body, a bottom layer formed of a material that is metallurgically compatible with the material of the machined surface of the support body, and an intermediate layer formed of a material that is metallurgically compatible with the material of the top layer and with the material of the bottom layer,
• wherein during use the first portion of the forming surface and the second portion of the forming surface cooperate to form a desired shape of the shaped product.

A process for building a tool, comprising:

• providing a support body fabricated from a first material;
• machining a portion of the first material from the support body so as to define a first portion of a forming surface of the tool;
• and
• depositing onto the support body a feature defining a second portion of the forming surface of the tool, comprising:
• depositing a layer of a second material onto the first material of the support body;
• depositing a layer of a third material onto the layer of the second material;
• and
• depositing a layer of a fourth material onto the layer of the third material, the layer of the fourth material defining a second portion of the forming surface of the tool,
• wherein the second material is metallurgically compatible with the first material, the fourth material is metallurgically incompatible with the first material, and the third material is metallurgically compatible with both the second material and the fourth material.

A process for repairing a defect in a tool, the tool having a support body fabricated from a first material and having a feature comprising a first metallic alloy layer deposited on the support body, a second metallic alloy layer deposited on the first metallic alloy layer, and a third metallic alloy layer deposited on the second metallic alloy layer, the defect being within the third metallic alloy layer, the process comprising:

• removing at least a portion of the third metallic alloy layer including the defect;
• depositing, where the at least the portion of the of the third metallic alloy layer was removed, a quantity of the third metallic alloy, the depositing performed by laser cladding and the quantity deposited being sufficient to exceed a design dimension of the feature;
• and
• machining the deposited third metallic alloy to achieve substantially the design dimension of the feature.

A process for re-purposing a tool, comprising:

• providing a tool having a forming surface with a first configuration, the tool fabricated from a first material;
• using laser cladding, depositing a feature onto the forming surface of the tool, comprising:
• depositing a layer of a second material onto the first material of the tool;
• depositing a layer of a third material onto the layer of the second material;
• and
• depositing a layer of a fourth material onto the layer of the third material, the layer of the fourth material defining a second portion of the forming surface of the tool,
• wherein the feature is deposited onto a portion of the forming surface that other than corresponds to a location of an existing feature of the forming surface, such that the forming surface has a second configuration different than the first configuration subsequent to depositing the feature.