Modularization of additive manufacturing systems Research topic 5.1
The benefits of additive manufacturing typically emerge when the component to be fabricated have complex geometry and is required in limited quantities. Industrial additive manufacturing increasingly utilizes powder-based laser beam melting (L-PBF) in these instances. The procedure relies on the incremental assembly of components via the selective fusion of tiny metal powders. The energy necessary for melting is delivered to the material using a laser beam.
Despite the swift advancement of the process, obstacles persist, particularly in the regulation of the melt pool. The quality of an additively created component is assessed based on parameters such as porosity, surface finish, and the mechanical properties of the material. All these criteria are substantially affected by the dynamics of the melt pool. The fundamental inquiry of this research unit is as follows: What techniques enhance the controllability of the melt pool? By dynamically altering the phase, amplitude, and polarization of laser light through beam shaping optics, the energy distribution of the laser beam can be modified. The research investigates the impact of particular energy distributions on the melt pool.
Challenges
The present challenge is to devise and establish the experimental configuration. The many elements must be incorporated within the laboratory's peripheral. This encompasses the acquisition of relevant technological components, a laser protection strategy, and the necessary enclosure. Furthermore, the
laboratory must guarantee the requisite power and water supplies for cooling purposes.
Alongside the organizational and administrative challenges, acquiring expertise in melt pool modeling will be essential later in the project. The university's resources cannot be employed in this instance. Furthermore, a framework for data gathering and analysis must be established. The question requires clarification regarding the appearance of process monitoring and the methodology for processing the collected data.
Research Approach
This research unit is positioned within fundamental research and employs a quantitative methodology. The experimental setup being created in the additive manufacturing lab at Esslingen University will facilitate the future additive construction of cubic samples. The experimental configuration includes multiple components. This features a 2KW laser source, a processing chamber, and beam shaping optics that modify the energy distribution of the laser beam. During the execution of the experiment, empirical data will be collected at various stages of the procedure. This includes:
- Material characteristics: particle dimensions and distribution, powder density, etc.
- Process data: laser intensity, energy allocation, scanning methodology, layer thickness, etc.
- Quality data: porosity, density, surface characteristics, microstructure, cracks, spatter formation, etc.
Prior to actual implementation, the behavior of the melt pool under the specified conditions must be analyzed by simulation.
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