Enhanced simulation and path planning for laser cladding with large spot diameter (T11#)

• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2026
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 236616214

The project “Enhanced simulation and path planning for laser cladding with large spot diameter” aims to enhance an FEM model for the laser cladding or Directed Energy Deposition (DED) process to simulate the dynamics of the melt pool and the solidification conditions at large laser spot diameters (up to 12 mm) more precisely. The focus is on industrial bimetal applications such as plain bearings, where high-quality coatings with optimized mechanical and tribological properties are required. By integrating larger laser spots, considering new material combinations, and developing an optimized application strategy, coatings with reduced waviness and improved quality are to be produced. Experimental data from Kugler Bimetall SA will be used to validate the model and support simulation-based process optimization. This increases the efficiency and precision of the DED process, which opens new possibilities for the industrial production of high-quality bimetal components.

• DFG Programme: Collaborative Research Centres (Transfer Project)
• Subproject of: SFB 1120: Precision manufacturing by controlling melt dynamics and solidification in production processes
• International Connection: Switzerland
• Applicant Institution: Rheinisch-Westfälische Technische Hochschule Aachen
• Business and Industry: Kugler Bimetal SA
• Project Head: Professor Dr.-Ing. Johannes Henrich Schleifenbaum