Online measurement based tool path generation toward integrated robotic laser cladding

Purpose – Refurbishing may be the most practical approach under the low volume production. This effort aims to achieve robotic laser cladding with the main purpose of achieving maximum processing flexibility, predictably high quality, lower maintenance and operating costs. This study aims to focus on online measurement and cladding path generation toward automatic laser cladding. Design/methodology/approach – Based on the specific requirements of automatic laser cladding, an approach was proposed toward an automatic laser cladding with powder injection for the refurbishment of components with free‐form surfaces. This study assessed the feasibility of integrating a non‐contact free‐form surface measurement system, an industrial robot, and an algorithm for generating cladding tool paths seamlessly. Findings – 3D laser scanning and laser cladding systems can be embedded into an existing robot motion control system. Online measurement based 3D surface reconstruction is a practical approach toward cladding tool path generation for on‐site refurbishment. Practical implications – Robotic laser cladding may be a potential application by integrating other measurement devices, such as temperature sensor based monitoring system. Originality/value – Refurbishing worn‐out components could have significant economic benefits. This study indicates that robotic laser cladding may potentially facilitate improved refurbishment of oversized components.