Flexible and highly dynamic beam shaping for Laser-Based Powder Bed Fusion of metals

Jonas Grünewald, Valentin Blickle, Matthias Allenberg-Rabe, Philipp Wagenblast, Katrin Wudy

Research output: Contribution to journalConference articlepeer-review

17 Scopus citations

Abstract

In state-of-the-art laser-based powder bed fusion processes, a thin layer of metal powder is typically melted by means of a small, Gaussian-shaped laser spot, limiting the stability and productivity of the process. The application of alternative beam shapes is a current research topic to stabilize, accelerate and extend laser-based powder bed fusion of metals, e.g. by tailoring the microstructure. Static beam shapes and sizes limit the theoretically possible process and geometry freedom. To overcome those limitations, an approach for flexible and highly dynamic beam shaping is presented. The experimental setup is based on two perpendicularly oriented acousto-optic deflectors. A synchronized superposition of the ultrafast deflections (switching rates above 100 kHz) is used to generate sequentially compound quasi-static beam shapes. This quasi-static beam shaping is combined with a state-of-the-art beam deflection system and proved to be a viable solution for improved processing. Specimens with a relative density of more than 99.5 % could be manufactured by applying three selected beam shapes. The proof of concept demonstrates the potential of the setup for flexible, fundamental research on the influence of alternative beam profiles in laser-based powder bed fusion of metals.

Original languageEnglish
Pages (from-to)65-70
Number of pages6
JournalProcedia CIRP
Volume111
DOIs
StatePublished - 2022
Event12th CIRP Conference on Photonic Technologies, LANE 2022 - Erlangen, Germany
Duration: 4 Sep 20228 Sep 2022

Keywords

  • AOD
  • Additive manufacturing
  • PBF-LB/M
  • acousto-optics
  • fast beam manipulation

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