The application of large-area metal clad regions is particularly valuable for manufacturing scenarios that require high-deposition buildups over large surface areas, such as rotating munition bands and other components that demand robust, high-quality material additions. These applications typically require the selective placement of a metal with different metallurgical properties than the base component. In many cases, the deposited material is intentionally harder or softer than the substrate to meet functional requirements such as wear resistance, controlled deformation, or improved interaction with mating components. For rotating munition bands specifically, these clad regions play a critical role in engaging cannon rifling, ensuring proper projectile spin, structural integrity, and predictable ballistic performance.

Traditionally, these deposit regions are produced using conventional arc welding–based processes. While effective, arc welding can introduce challenges including high heat input, increased dilution at the joint interface, variability in deposit quality, and limitations in achievable deposition efficiency and control. As performance and quality requirements continue to increase, there is growing interest in alternative deposition approaches that offer improved process stability and metallurgical outcomes.

The project discussed in this presentation focused on developing and evaluating advanced deposition processes such as laser-based strip cladding as potential replacements for the current arc welding approach. The primary objectives included the development of stable and repeatable processes with optimized setup and parameters, reduced material dilution, high deposit quality, and competitive deposition rates. This talk will present the background, objectives, and key outcomes of this innovative laser processing effort.