Laser metal deposition device with wire force detection by a multi-axis force sensor and method

A laser metal deposition device comprising:

• a wire nozzle for delivering a wire to be deposited on a substrate,
• a laser source for delivering a laser beam configured to melt the wire,
• a multi-axes force sensor configured to determine the forces between the wire and the substrate, and
• a controller adapted to control, based on the measured forces by the force sensor, at least one of:
• output power of the laser source, rate of relative movement of the wire nozzle and laser beam with respect to the substrate, or displacement of the wire and/or wire nozzle with respect to the laser beam in at least one axis.

A method for operating a laser metal deposition device comprising:

• providing a wire to be deposited on a substrate via a wire nozzle,
• providing a laser beam to the substrate via a laser source,
• displacing the wire and laser beam relative the substrate to deposit melted wire in a direction of travel,
• measuring the forces acting on the wire in multiple axes via a multi-axis force sensor, and
• controlling based on the forces measured by the multi-axis force sensor at least one of:
• output power of the laser source, rate of relative movement of the wire nozzle and laser beam with respect to the substrate, or location of the wire and/or wire nozzle with respect to the laser beam in at least one axis.

A method of detrimental process mode detection and recovery for a laser metal deposition device, the device comprising a wire nozzle for providing a wire to be deposited on a substrate, and a laser source for providing a laser beam;

• the method comprising:
• measuring the forces acting on the wire in multiple axes via a multi-axis force sensor, and
• based on the forces measured by the force sensor, controlling at least one of:
• output power of the laser source, current supplied to the wire, rate of relative movement of the wire nozzle and laser beam with respect to the substrate, or location of the wire nozzle with respect to the laser beam in at least one axis.