Challenges in the design of portable laser repair systems

Laser processing is well suited to implementation in high volume applications where a dedicated processing cell is used. Given their ease of automation, low heat input, and fiber optic delivery lasers are an attractive tool for repair processes. However, there are unique challenges to implementing laser systems in existing work areas. On-going design efforts at ARL Penn State are addressing the issues of laser safety enclosures, laser beam delivery/optics, shielding gas delivery, out of position processing, and the delivery of wire or powder cladding materials, and developing systems for safe operation in these work environments. Two portable, robotic laser clad repair systems designed to be brought to the component being repaired are discussed along with the challenges and solutions associated with development of safe portable robotic laser repair. The first is a deep-bore wire based laser cladding system for repairing valve components. The second is a high power reflective optics cladding system for repair of large shafting components.