| 1. |
- Brandau, Benedikt, et al.
(författare)
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Absorbance determination of a powder bed by high resolution coaxial multispectral imaging in laser powder bed fusion
- 2024
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Ingår i: Optics and Laser Technology. - : Elsevier. - 0030-3992 .- 1879-2545. ; 168
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Tidskriftsartikel (refereegranskat)abstract
- This study presents an approach for in-situ monitoring of laser powder bed fusion. Using standard laser optics, coaxial high-resolution multispectral images of powder beds are acquired in a pre-objective scanning configuration. A continuous overview image of the entire 114 × 114 mm powder bed can be generated, detecting objects down to 20 µm in diameter with a maximum offset of 22–49 µm. Multispectral information is obtained by capturing images at 6 different wavelengths from 405 nm to 850 nm. This allows in-line determination of the absorbance of the powder bed with a maximum deviation of 2.5% compared to the absorbance spectra of established methods. For the qualification of this method, ray tracing simulations on powder surfaces and tests with 20 different powders have been carried out. These included different particle sizes, aged and oxidized powders.
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| 2. |
- Brandau, Benedikt, et al.
(författare)
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Absorbance study of powder conditions for laser additive manufacturing
- 2022
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Ingår i: Materials & design. - : Elsevier. - 0264-1275 .- 1873-4197. ; 216
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Tidskriftsartikel (refereegranskat)abstract
- Absorbance is often used for simulations or validation of process parameters for powder-based laser materials processing. In this work, the absorbance of 39 metal powders for additive manufacturing is determined at 20 laser wavelengths. Different grain sizes and aging states for: steels, aluminum alloys, titanium alloys, Nitinol, high entropy alloy, chromium, copper, brass and iron ore were analyzed. For this purpose, the absorbance spectrum of the powders was determined via a dual-beam spectrometer in the range of λ = 330 - 1560 nm. At the laser wavelengths of λ = 450 nm, 633 nm and 650 nm, the absorbance averaged over all materials was found to increase by a factor of 2.4 up to 3.3 compared to the usual wavelength of λ = 1070 nm, with minimal variations in absorbance between materials. In the investigation of the aged or used powders, a loss of absorbance was detectable. Almost no changes from the point of view of processing aged and new AlSi10Mg powders, is expected for laser sources with λ = 450 nm. The resulting measurements provide a good basis for process parameters for a variety of laser wavelengths and materials, as well as a data set for improved absorbance simulations.
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| 3. |
- Brandau, Benedikt, et al.
(författare)
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Angular dependence of coaxial and quasi-coaxial monitoring systems for process radiation analysis in laser materials processing
- 2022
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Ingår i: Optics and lasers in engineering. - : Elsevier. - 0143-8166 .- 1873-0302. ; 155
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Tidskriftsartikel (refereegranskat)abstract
- Process monitoring is becoming increasingly important in laser-based manufacturing and is of particular importance in the field of additive manufacturing [e.g. Laser Powder Bed Fusion (LPBF)]. Process monitoring enables a reduction of production costs and a lower time-to-market. Furthermore, the data can be used to create a digital twin of the workpiece. There are already many established processing head-integrated monitoring systems for such applications as the multispectral analysis of process radiation. However, the monitoring of complex signals in systems with F-Theta scanner lenses is very challenging and requires specially adapted optics or measuring sensors.In this paper a potential arrangement for spectroscopy-based process monitoring in pre-objective scanning is presented. The process radiation was monitored using a coaxial and a quasi-coaxial observation system. The measurements were carried out on both a solid and a powder coated sample of 2.4668 (Inconel 718) to show the potential use of these systems in laser-based additive manufacturing. In order to obtain comprehensive data about the process signal, the process zone was analyzed at different angles of incidence (AOI) of the laser using a high-speed camera (HSI) and a spectrometer. The connection between the HSI and the spectral measurements is discussed. The ionization of the material and the formation of a plasma was observed and found to lose intensity as the angle of incidence increases. A model of the system that demonstrates the intensity of the emitted radiation of the plasma was created. It enables the measured values to be corrected. The corrected measurement data can be used to detect impurities or a non-ideal energy input across the entire processing field, which is a move towards robust process monitoring.
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| 4. |
- Brandau, Benedikt
(författare)
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Spectral analysis in laser powder bed fusion
- 2022
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- This thesis is about the investigation of the spectral interaction of electromagnetic radiation with metal powders. For this purpose, spectral data of powders for laser powder bed fusion processes are investigated in three papers using different techniques. In paper A the spectral radiation behavior of the laser interaction zone is considered, in paper B and C the absorbance behavior of different metal powders depending on their state and measurement method. Paper A investigates the spectral signal of the process light generated by laser material interaction in laser powder bed fusion. The detection is performed by a coaxially guided measuring beam and a quasi-coaxial measuring beam simultaneously guided by another scanning optics. The signal characteristics depend on the angle of incidence of the measuring beam to the laser material interaction zone. Using high-speed recordings and optical simulations, a model for describing the signal behavior could be determined. The measured spectral intensity distribution representing the degree for energy coupling can be corrected with a correction factor over the whole field for solid materials. This correction includes a function describing the numerical aperture of the measuring channel and the laser intensity on the working field. For the investigated powder, the measurement signal fluctuated strongly and no transferable model could be formed. The reason for this was the different absorbance behavior of the powders investigated. Paper B therefore deals in detail with the spectral absorbance behavior of metal powders for additive manufacturing. Using a high-precision spectrometer, 39 powders were measured reflectively over a wide spectral range and the absorbance determined. By varying the degree of use, aging, grain size and impurities, various influence parameters are determined experimentally and discussed theoretically. Based on 20 derived laser wavelengths, technically usable wavelengths with better process efficiency and stability are proposed. From the obtained absorbance, the efficiency of energy coupling can be estimated and form a broad data base for the optimization of laser parameters. In order to perform the absorbance determinations also in situ in a laser powder bed fusion system paper C describes a possibility of an inline absorbance determination by high resolution coaxial imaging. A method is discussed for geometrically correct and gapless imaging of the processing plane, recorded through the laser optics. By imaging at six different wavelengths, metal powders can be distinguished by their absorbance spectrum and impurities can be detected. In an experimental implementation the functionality of the method is proven. The results are validated by optical simulations, ray tracing and comparative measurements with a high-precision spectrometer.
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| 5. |
- Bunaziv, Ivan, et al.
(författare)
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Filler metal distribution and processing stability in laser-arc hybrid welding of thick HSLA steel
- 2020
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Ingår i: Journal of Manufacturing Processes. - : Elsevier. - 1526-6125. ; 54, s. 228-239
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Tidskriftsartikel (refereegranskat)abstract
- Welds made by high power laser beam have deep and narrow geometry. Addition of filler wire by the arc source, forming the laser-arc hybrid welding (LAHW) process, is very important to obtain required mechanical properties. Distribution of molten wire throughout the entire weld depth is of concern since it tends to have low transportation ability to the root. Accurate identification of filler metal distribution is very challenging. Metal-cored wires can provide high density of non-metallic inclusions (NMIs) which are important for acicular ferrite nucleation. Accurate filler distribution can be recognized based on statistical characterization of NMIs in the weld. In the present study, it was found that the amount of filler metal decreased linearly towards the root. The filler metal tends to accumulate in the upper part of the weld and has a steep decrease at 45–55 % depth which also has wavy pattern based on longitudinal cuts. Substantial hardness variation in longitudinal direction was observed, where in the root values can reach > 300 HV. Excessive porosity was generated at 75 % depth due to unstable and turbulent melt flow based on morphology of prior austenite grains. The delicate balance of process parameters is important factor for both process stability and filler metal distribution.
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| 6. |
- Da Silva, Adrien, et al.
(författare)
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Acceleration of metal drops in a laser beam
- 2021
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Ingår i: Applied Physics A. - : Springer. - 0947-8396 .- 1432-0630. ; 127:1
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Tidskriftsartikel (refereegranskat)abstract
- Different processes require the detachment of metal drops from a solid material using a laser beam as the heat source, for instance laser drop generation or cyclam. These techniques imply that the drops enter the laser beam, which might affect their trajectory. Also, many laser processes such as laser welding or additive manufacturing generate spatters that can be accelerated by the laser beam during flight and create defects on the material. This fundamental study aims at investigating the effects of a continuous power laser beam on the acceleration of intentionally detached drops and unintentionally detached spatters. Two materials were studied: 316L steel and AlSi5 aluminium alloy. High-speed imaging was used to measure the position of the drops and calculate their acceleration to compare it to theoretical models. Accelerations up to 11.2 g could be measured. The contributions of the vapor pressure, the recoil pressure, and the radiation pressure were investigated. The recoil pressure was found to be the main driving effect but other phenomena counteract this acceleration and reduce it by an order of magnitude of one to two. In addition, two different vaporization regimes were observed, resulting respectively in a vapor plume and in a vapor halo around the drop.
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| 7. |
- Da Silva, Adrien, et al.
(författare)
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Additive Manufacturing by laser-assisted drop deposition from a metal wire
- 2021
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Ingår i: Materials & design. - : Elsevier. - 0264-1275 .- 1873-4197. ; 209
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Tidskriftsartikel (refereegranskat)abstract
- The subject of Additive Manufacturing includes numerous techniques, some of which have reached very high levels of development and are now used industrially. Other techniques such as Micro Droplet Deposition Manufacture are under development and present different manufacturing possibilities, but are employed only for low melting temperature metals. In this paper, the possibility of using a laser-based drop deposition technique for stainless-steel wire is investigated. This technique is expected to be a more flexible alternative to Laser Metal Wire Deposition. Laser Droplet Generation experiments were carried out in an attempt to accurately detach steel drops towards a desired position. High-speed imaging was used to observe drop generation and measure the direction of detachment of the drops. Two drop detachment techniques were investigated and the physical phenomena leading to the drop detachment are explained, wherein the drop weight, the surface tension and the recoil pressure play a major role. Optimised parameters for accurate single drop detachment were identified and then used to build multi-drop tracks. Tracks with an even geometry were produced, where the microstructure was influenced by the numerous drop depositions. The tracks showed a considerably higher hardness than the base wire, exhibiting a relatively homogeneous macro-hardness with a localised softening effect at the interfaces between drops.
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| 8. |
- Da Silva, Adrien
(författare)
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Aspects of material and heat transfer in drop- and powder-based laser additive manufacturing
- 2023
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Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Additive Manufacturing became a major research topic and part of industrial production in the past years. Numerous techniques now allow to build 3D structures with a wide choice of materials. When it comes to processing of metals, a laser beam is often used as a heat source to melt either a wire or powder. Novel approaches of material deposition are also developed, such as Laser Droplet Generation, which could potentially be applied to Additive Manufacturing. During the process, the laser beam light is partly absorbed by the material, and is then converted to heat, which can induce melting and even vaporization. Additive Manufacturing presents several processing challenges, such as the recoil pressure acting on the drops and powder particles that affects their trajectory. Storage and recycling of the powders is also an important aspect since the powder properties are changed through aging. Another challenge is the adjustment of process parameters according to varying deposition conditions, where the use of process monitoring techniques is crucial.Therefore, this thesis aims at better understanding (i) the effects of recoil pressureon metal drops and powder particles, (ii) powder aging and its effects on the process, and (iii) process optimisation and stability via monitoring. In the six adjoined papers, high-speed imaging and thermal imaging were used to observe laser Additive Manufacturing processes involving both metal drops and powders. The videos enabled to observe drop detachments, measure trajectories, plot powder density maps, quantify powder catchment in the melt pool, measure themelt pool geometry, detect oxides, and extract cooling rates. The experimental results were supplemented with material analysis and theoretical calculations of thermodynamics, recoil pressure and surface tension.These studies allowed to conclude that the recoil pressure induced by laser irradiation on a drop or a powder particle can have some significant effect such as acceleration, change of trajectory, or disintegration. However, these effects seem to be considerably lower than what theoretical models predict. It was also found that the recoil pressure can be used to accurately detach drops from a wire, which was utilised as a new material deposition method for Additive Manufacturing. In Directed Energy deposition, it was showed that aging of the aluminium powder feedstock should be avoided since it induces high porosity, high dilution and decreased mechanical properties. Finally, to guarantee a defect-free deposition during the whole process, it was demonstrated that a thermal camera can be used to monitor the melt pool size, which allows to apply appropriate laser power adjustments to compensate for changing building conditions.
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| 9. |
- Da Silva, Adrien, et al.
(författare)
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Influence of aluminium powder aging on Directed Energy deposition
- 2022
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Ingår i: Materials & design. - : Elsevier. - 0264-1275 .- 1873-4197. ; 218
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Tidskriftsartikel (refereegranskat)abstract
- The use of aluminium alloys for Additive Manufacturing is of high interest for advanced geometries and lightweight applications. In Directed Energy Deposition, a powder stock is processed with a laser beam, which offers a high process flexibility. However, aging of the powder feedstock during storage or after recycling remains fundamentally challenging for aluminium alloys because of their sensitivity to oxida-tion and porosity. In order to investigate these effects, AlSi10Mg powder batches were aged in different conditions and processed by Directed Energy Deposition. The results showed that powder aging does not significantly change the particle size or morphology, but it introduces more oxygen and hydrogen in the powder. The oxidation of the particles reduces the laser beam absorbance of the powder and increases wetting of the melt pool, which affects the track geometry. A 3.5 to 4.2 times higher porosity was observed in the material deposited from aged powder, which are most likely hydrogen pores causedby the increased hydrogen content in the aged powder. The tensile properties of the parts built with aged powder showed 19.0% lower yield strength, 14.2% lower ultimate strength and 99.2% higher elongation, which are most likely the results of the coarser microstructure and increased porosity.
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| 10. |
- Da Silva, Adrien
(författare)
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Laser-induced recoil pressure on metal drops and powder particles
- 2021
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Additive Manufacturing became a major research topic and part of industrial production in the past years. Numerous techniques now allow to build 3D structures with a wide choice of materials. When it comes to processing of metals, a laser beam is often used as a heat source to melt either a wire or powder, where the trajectory of spatters and powder particles can be affected by the laser beam radiation. Laser beam irradiation is partly absorbed by the material, and is then converted to heat, which can cause melting and even vaporization. The vaporization of material induces a recoil pressure on the melt pool, which affects its geometry and dynamics. However, the effects of the recoil pressure on airborne objects such as drops and powder particles are still relatively unknown. Their different sizes and boundary conditions compared to a melt pool might affect their behaviour under high laser beam radiation. Therefore, this thesis aims at better understanding the effects of the recoil pressure on metal drops and powder particles, as well as their impacts on Additive Manufacturing processes, especially Directed Energy Deposition and Laser Metal Wire Deposition. In the three adjoined papers, high-speed imaging was used to observe (i) powder blown through a laser beam, (ii) drops falling in a laser beam, and (iii) drops detaching from a wire in a laser beam. The videos enabled to calculate the acceleration of powder particles and drops of different sizes, the density map of the powder stream, and the detachment direction of the drops. The experimental results were completed with theoretical calculations of thermodynamics, recoil pressure and surface tension. These studies allowed to conclude that the acceleration induced by the recoil pressure on a drop or a powder particle increases with decreased size. Moreover, the recoil pressure causes a slight deviation of the powder stream in Directed Energy Deposition that can induce a better powder focusing. The recoil pressure can also cause the disintegration of powder particles in the laser beam. Finally, it was shown that the recoil pressure can be used to detach drops on demand from a wire and accelerate them towards the substrate where they can be strategically deposited for building additive structures.
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