The effect of cladding of Ti-6Al-4V knife edges using wires and a CO2 laser power source was investigated. This method of cladding, in combination with conventional atmospheric shielding techniques, permits continuous deposition of thick (> 1mm) cladding of acceptable porosity and microstructural quality. The cladding width increased to 0.76–0.81mm irrespective of the knife edge width of 0.350–0.76mm. Continuous deposition of multiple layers was possible, at 0.125–0.150mm increase in thickness per pass, at part linear speeds as high as 762 mm/min. While the process is sensitive to practical considerations of wire feed, knife edge and laser alignment, no evidence of damage to the substrate from laser reflection was observed.

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