Advancement Of Selective Laser Melting By Laser Beam Shaping

Selective Laser Melting (SLM), also referred to as Laser Powder Bed Fusion (L-PBF), offers significant advantages for the manufacturing of complex, high-quality parts. However, its market share is still small compared to conventional manufacturing technologies. Major drawbacks hindering an industrial ramp-up are low productivity, high part costs and issues with quality and reproducibility. Comprehensive research has been done to overcome these challenges, but little attention has been paid to addressing them by optimizing the laser beam profile. Therefore, the author examines the effect of the laser beam profile on the productivity and process stability through both numerical and experimental investigations. The results show clear advantages an optimized laser beam profile offers. The content First comprehensive research on the effect of the laser beam profile on SLM process Understand the effect of the laser beam profile on the process stability and feasible productivity of the SLM process Discover the benefits in terms of manufacturing costs and time that are offered by an optimized laser beam profile The author Tim Marten Wischeropp studied mechanical engineering at the Technical University of Hamburg (TUHH), Germany. After graduating with a focus on product development, he worked as a research fellow at the Institute of Laser and System Technologies (TUHH) as well as group leader for 3D printing at the LZN Laser Zentrum Nord GmbH. Since 2018 he leads the design department at the Fraunhofer Institution for Additive Manufacturing Technologies IAPT.

Selective Laser Melting (SLM), also referred to as Laser Powder Bed Fusion (L-PBF), offers significant advantages for the manufacturing of complex, high-quality parts. However, its market share is still small compared to conventional manufacturing technologies. Major drawbacks hindering an industrial ramp-up are low productivity, high part costs and issues with quality and reproducibility. Comprehensive research has been done to overcome these challenges, but little attention has been paid to addressing them by optimizing the laser beam profile. Therefore, the author examines the effect of the laser beam profile on the productivity and process stability through both numerical and experimental investigations. The results show clear advantages an optimized laser beam profile offers.

Laser Beam Shaping: Theory and Techniques addresses the theory and practice of every important technique for lossless beam shaping. Complete with experimental results as well as guidance on when beam shaping is practical and when each technique is appropriate, the Second Edition is updated to reflect significant developments in the field. This authoritative text: Features new chapters on axicon light ring generation systems, laser-beam-splitting (fan-out) gratings, vortex beams, and microlens diffusers Describes the latest advances in beam profile measurement technology and laser beam shaping using diffractive diffusers Contains new material on wavelength dependence, channel integrators, geometrical optics, and optical software Laser Beam Shaping: Theory and Techniques, Second Edition not only provides a working understanding of the fundamentals, but also offers insight into the potential application of laser-beam-profile shaping in laser system design.

The practice of shaping the irradiance profile of laser beams goes back more than three decades, and the applications of beam shaping are as diverse as they are numerous. However, until Dickey and Holswade's groundbreaking and highly popular Laser Beam Shaping: Theory and Techniques was published, there was no single, detailed treatment available on the underlying theory and basic techniques of beam shaping. Building on the foundations of this previous work, these esteemed editors have teamed with recognized expert David L. Shealy to produce the first in-depth account of beam shaping applications and design. Laser Beam Shaping Applications details the important features of beam shaping and exposes the subtleties of the theory and techniques that are best demonstrated through proven applications. In chapters contributed by prominent, active leaders in their respective specialties, the book discusses applications in lithography, laser printing, optical data storage, stable isotope separation, adaptive mirrors, and spatially dispersive lasers. The contributors share major insights, knowledge, and experience, reveal the advantages of the technologies, and include extensive references to the literature. The book concludes with a summary of beam shaping theory and techniques as well as the history of the field. Providing practical expertise, Laser Beam Shaping Applications is an extremely helpful guide to improving current laser processes, optimizing application-specific technologies, and advancing future development in the field.

Additive manufacturing (AM) is one of the manufacturing processes that warrants the attention of industrialists, researchers, and scientists. AM has the ability to fabricate materials to produce parts with complex shapes without any theoretical restrictions combined with added functionalities. Selective laser melting (SLM), also known as laser-based powder bed processing (LPBF), is one of the main AM process that can be used to fabricate wide variety of materials that are Al-, Ti-, Fe-, Ni-, Co-, W-, Ag-, and Au-based, etc. However, several challenges need to be addressed systematically, such as development of new materials that suit the SLM process conditions so the process capabilities can be fully used to produce new properties in these materials. Other issues in the field are the lack of microstructure–property correlations, premature failure, etc. Accordingly, this Special Issue (book) focuses mainly on the microstructure-correlation in three different alloys: AlSi10Mg, Ti6Al4V, and 304L stainless steel, where six articles are presented. Hence, this Special Issue outlines microstructure–property correlations in the SLM processed materials and provides a value addition to the field of AM.

Special topic volume with invited peer-reviewed papers only

This book reports on cutting-edge research and developments in manufacturing, giving a special emphasis to solutions fostering automation and sustainability. Topics cover manufacturing process optimization, remanufacturing, machines and mechanical design, CAD/CAM/CAE, materials characterization and processing, measurement and predictive maintenance techniques. Further topics include artificial intelligence and IoT in manufacturing, robotics, and cutting-edge issues in Industry 4.0/5.0. Based on proceedings of the 32nd edition of the International Conference on Flexible Automation and Intelligent Manufacturing, FAIM 2023, held on June 18 – 22, 2023, in Porto, Portugal, this first volume of a 2-volume set provides academics and professionals with extensive, technical information on trends and technologies in manufacturing, yet it also discusses challenges and practice-oriented experience in all the above-mentioned areas.

Laser powder bed fusion of metals is a technology that makes use of a laser beam to selectively melt metal powder layer-by-layer in order to fabricate complex geometries in high performance materials. The technology is currently transforming aerospace and biomedical manufacturing and its adoption is widening into other industries as well, including automotive, energy, and traditional manufacturing. With an increase in design freedom brought to bear by additive manufacturing, new opportunities are emerging for designs not possible previously and in material systems that now provide sufficient performance to be qualified in end-use mission-critical applications. After decades of research and development, laser powder bed fusion is now enabling a new era of digitally driven manufacturing. Fundamentals of Laser Powder Bed Fusion of Metals will provide the fundamental principles in a broad range of topics relating to metal laser powder bed fusion. The target audience includes new users, focusing on graduate and undergraduate students; however, this book can also serve as a reference for experienced users as well, including senior researchers and engineers in industry. The current best practices are discussed in detail, as well as the limitations, challenges, and potential research and commercial opportunities moving forward. Presents laser powder bed fusion fundamentals, as well as their inherent challenges Provides an up-to-date summary of this advancing technology and its potential Provides a comprehensive textbook for universities, as well as a reference for industry Acts as quick-reference guide