Laser Additive Manufacturing for the Realization of New Material Concepts

In additive manufacturing processes, components are built up in layers from liquids, powders, wires or foils using chemical or physical processes. Direct energy deposition (DED) or powder bed fusion (PBF) can be used as additive manufacturing processes in which metal powder or wires are used to print dense metal layers on substrates or on freeform surfaces of existing components [1]. Metal powder (pure elements, element mixtures, master alloys) or metal wires are melted at high speed and instantaneously deposited in layers on respective metallic substrates. In case of the so-called laser cladding [2], this technology is generally used for applying coatings or for tool repairs. Compared to subtractive processes, additive processes save time and resources, as the material is only added where it is needed. Established steels, nickel-based alloys or titanium alloys are typically used. However, it is also possible to obtain completely new materials by in-situ alloying of powder mixtures or to create material gradients by changing the powder mixture composition during the build-up [3]. High entropy alloys (HEAs) represent a new research field for future applications. These are formed from a large number of elements, all of which are present in similarly strong concentrations e.g., alloys consisting of zirconium, niobium, hafnium, tantalum or tungsten [4]. The alloys formed can generally be single-phase as well as multi-phase mixed crystals. HEAs can often combine high strength and very good ductility. In-situ alloying offers the unique possibility of fast material screening for the future production of new metallic components with outstanding mechanical properties at high temperatures. For a long time, the manufacture of refractory alloys was limited to vacuum arc remelting because of their high melting points. With laser-based methods, these metals are locally melted by the focused laser beam and deposited additively. In addition to material development, additive manufacturing offers great design freedom in component design, which can be used, for example, for the development of load-optimized designs based on the bionic principle [5]. To add up to the versatility of additive manufacturing, laser post-processes can be used to modify the resulting surfaces of parts produced with such technology [6-9]. The different types of laser sources commercially available assure their suitability in a wide range of applications, with continuous wave (cw) lasers being often used for reduction of surface roughness, while pulsed lasers being applied in the modification of surface functionalities and to enhance the geometry accuracy. Even with the prospect of being able to replace certain steps of the additive manufacturing process chain, adopting laser post-processes as an additional step can also be proved beneficial when specific characteristics are required in localized areas of the final built components

Avaliação do consumo de energia no processo de fresamento de cavidades 2 1/2D para diferentes tipos de trajetórias

Dissertação (mestrado) - Universidade Federal de Santa Catarina, Centro Tecnológico, Programa de Pós-Graduação em Engenharia Mecânica, Florianópolis, 2016.O aumento da população, juntamente com a crescente escassez dos recursos naturais, vem aumentando a intensidade dos impactos ambientais. Estes fatores têm gerado um aumento na consciência social, forçando os órgãos reguladores a encorajar a diminuição do consumo de energia, cuja geração está intimamente ligada a diversas questões ambientais. Este encorajamento se tornou um incentivo às pesquisas de métodos para a redução do consumo de energia, principalmente nos setores onde os maiores consumos são observados, que inclui o setor de manufatura. Especificamente o processo de usinagem, é responsável por grande carga ambiental associada tanto ao consumo de energia, quanto aos fluidos de corte utilizados e outros fatores. Uma forma de tornar os processos de usinagem mais sustentáveis é mediante a redução do consumo de energia, que pode ser obtida reduzindo-se o caminho percorrido pela da ferramenta de corte. Este trabalho fornece uma avaliação do consumo de energia durante o processo de fresamento de cavidades com duas ferramentas para diferentes trajetórias. A geração das trajetórias foi realizada utilizando-se um software CAM (Manufatura Assistida por Computador) e três tipos trajetórias foram geradas para comparação, sendo elas: paralela ao contorno, ziguezague e uma combinação de trajetória trocoidal e paralela ao contorno. As trajetórias estudadas apresentaram uma variação significativa no consumo total de energia ativa para cada uma das ferramentas. Os resultados comprovam a importância de gerar trajetórias que diminuam o caminho percorrido pela ferramenta e o tempo de usinagem, além de destacar a necessidade da seleção adequada dos parâmetros de corte e das demais variáveis envolvidas na usinagem, de maneira a tornar o processo mais sustentável.Abstract : The increase in population, coupled with the increasing scarcity of natural resources has increased the intensity of environmental impacts. These factors have led to an increase in social consciousness, forcing regulators to encourage the reduction of energy consumption, whose generation is closely linked to several environmental issues. This encouragement has become an incentive to research methods for reducing energy consumption, especially in sectors where the greatest consumption are observed, including the manufacturing sector. Specifically the machining process, is responsible for much environmental burden associated with both energy consumption, the cutting fluid used and other factors. One way to make the most sustainable machining processes is by reducing energy consumption, which can be obtained by reducing the path of the cutting tool. This paper provides an assessment of energy consumption during the cavity milling process with two tools for different paths. The generation of trajectories was performed using a software CAM (Computer Aided Manufacturing) and three types of trajectories were generated for comparison, these being: parallel to the contour, zigzag and a combination of trochoidal and parallel to the contour. The trajectories studied showed a significant variation in the total consumption of active power for each tool. The results prove the importance of generating trajectories that reduce the path taken by the tool and the machining time, and highlight the need for proper selection of cutting parameters and other variables involved in the machining process, in order to make it more sustainable

Laser-assisted post-processing of additive manufactured metallic parts

Laser-assisted additive manufacturing (AM) is the process of successively melting thin layers of material using a laser source to produce a three dimensional device or product. From the many technologies available, only a few can produce metallic parts that fulfil the requirements of industrial applications. Ultrafast laser machining is a new and promising technical approach for post-processing AM parts since laser ablation and surface modification processes could be applied with high accuracy for trimming shape and functionality, i.e., edge quality and wettability. The impact of different ultrafast laser parameters is evaluated for AM samples, which are examined for surface roughness before and after the laser-assisted post-processes. For all the parameters tested, the use of ultrafast laser resulted in a homogeneous material ablation of the samples’ surfaces. For the investigated parameter range, the AM building tracks were still maintained even after ultrafast laser post-processing. The achieved results showed the formation of self-organized porous structures at low laser scan velocities leading to an enhanced surface roughness. For higher scan velocities characteristic nano ripples might be induced having no significant impact on the measured surface roughness

Multiobjective Optimization of Laser Polishing of Additively Manufactured Ti-6Al-4V Parts for Minimum Surface Roughness and Heat-Affected Zone

Metal parts produced by additive manufacturing often require postprocessing to meet the specifications of the final product, which can make the process chain long and complex. Laser post-processes can be a valuable addition to conventional finishing methods. Laser polishing, specifically, is proving to be a great asset in improving the surface quality of parts in a relatively short time. For process development, experimental analysis can be extensive and expensive regarding the time requirement and laboratory facilities, while computational simulations demand the development of numerical models that, once validated, provide valuable tools for parameter optimization. In this work, experiments and simulations are performed based on the design of experiments to assess the effects of the parametric inputs on the resulting surface roughness and heat-affected zone depths. The data obtained are used to create both linear regression and artificial neural network models for each variable. The models with the best performance are then used in a multiobjective genetic algorithm optimization to establish combinations of parameters. The proposed approach successfully identifies an acceptable range of values for the given input parameters (laser power, focal offset, axial feed rate, number of repetitions, and scanning speed) to produce satisfactory values of Ra and HAZ simultaneously

Laser surface modification and polishing of additive manufactured metallic parts

The combination of additive manufacturing (AM) and subsequent laser polishing is a technical approach with high flexibility in comparison to conventional processes. AM parts often present the need of post-processing due to surfaces with roughness higher than the admissible for most applications. The laser polishing consists in ablation and melting of a small amount of material, through laser irradiation, which is redistributed to create a surface with low roughness and probably new functionalities. Besides the flexibility, laser polishing presents high processing speed and capability for localized surface treatment. In this study, the resulting characteristics of AM parts irradiated by laser sources with different technical features are investigated and discussed. The parameters applied were the pulse duration, scan speed, repetition rate and average laser power. To evaluate the impact of laser processing on the material the microstructure and surface roughness were analysed and correlated to the process parameters

Effect of process parameters on surface texture generated by laser polishing of additively manufactured Ti-6Al-4V

Although there have been numerous attempts to define how different laser polishing parameters affect the generated surface roughness, there has been no detailed investigation of how their effects can be combined to optimize the process. This paper applies statistical analysis to model and predict the resulting surface roughness for laser post-processing of components made of Ti-6Al-4V and produced by laser powder bed fusion. This model is based on analysis of a wide ranging experimental programme investigating how the interaction of the governing parameters, i.e., laser power, number of repetitions, axial feed rate, scanning speed, and focal position, affected surface roughness. The experimental programme was the result of a robust Design of Experiments analysis and experimental analysis using ANOVA. It is expected that the outcomes will contribute towards the understanding of how the governing parameters influence the laser polishing process and final surface roughness, and would be a tool for optimizing their selection. The results of the ANOVA (analysis of variance) revealed that the most significant parameters are scanning speed followed by laser power and then axial feed rate. In addition, a clear tendency for the estimated Ra to decrease with the increase in laser power at lower values of axial feed rate and of scanning speed, and a focal position in the region of 2 mm. It is noted that the process parameters were varied over wide ranges, including extreme values, which made it difficult to accurately model the dependent variable over the full range of experimental trials

Two-Step Laser Post-Processing for the Surface Functionalization of Additively Manufactured Ti-6Al-4V Parts

Laser powder bed fusion (LPBF) is one of the additive manufacturing methods used to build metallic parts. To achieve the design requirements, the LPBF process chain can become long and complex. This work aimed to use dierent laser techniques as alternatives to traditional post-processes, in order to add value and new perspectives on applications, while also simplifying the process chain. Laser polishing (LP) with a continuous wave laser was used for improving the surface quality of the parts, and an ultrashort pulse laser was applied to functionalize it. Each technique, individually and combined, was performed following distinct stages of the process chain. In addition to removing asperities, the samples after LP had contact angles within the hydrophilic range. In contrast, all functionalized surfaces presented hydrophobicity. Oxides were predominant on these samples, while prior to the second laser processing step, the presence of TiN and TiC was also observed. The cell growth viability study indicated that any post-process applied did not negatively aect the biocompatibility of the parts. The presented approach was considered a suitable post-process option for achieving dierent functionalities in localized areas of the parts, for replacing certain steps of the process chain, or a combination of both

Laser-Treated Surfaces for VADs: From Inert Titanium to Potential Biofunctional Materials

Laser-treated surfaces for ventricular assist devices. Impact Statement. This work has scientific impact since it proposes a biofunctional surface created with laser processing in bioinert titanium. Introduction. Cardiovascular diseases are the world’s leading cause of death. An especially debilitating heart disease is congestive heart failure. Among the possible therapies, heart transplantation and mechanical circulatory assistance are the main treatments for its severe form at a more advanced stage. The development of biomaterials for ventricular assist devices is still being carried out. Although polished titanium is currently employed in several devices, its performance could be improved by enhancing the bioactivity of its surface. Methods. Aiming to improve the titanium without using coatings that can be detached, this work presents the formation of laser-induced periodic surface structures with a topology suitable for cell adhesion and neointimal tissue formation. The surface was modified by femtosecond laser ablation and cell adhesion was evaluated in vitro by using fibroblast cells. Results. The results indicate the formation of the desired topology, since the cells showed the appropriate adhesion compared to the control group. Scanning electron microscopy showed several positive characteristics in the cells shape and their surface distribution. The in vitro results obtained with different topologies point that the proposed LIPSS would provide enhanced cell adhesion and proliferation. Conclusion. The laser processes studied can create new interactions in biomaterials already known and improve the performance of biomaterials for use in ventricular assist devices

Multiobjective Optimization of Laser Polishing of Additively Manufactured Ti-6Al-4V Parts for Minimum Surface Roughness and Heat-Affected Zone

Metal parts produced by additive manufacturing often require postprocessing to meet the specifications of the final product, which can make the process chain long and complex. Laser post-processes can be a valuable addition to conventional finishing methods. Laser polishing, specifically, is proving to be a great asset in improving the surface quality of parts in a relatively short time. For process development, experimental analysis can be extensive and expensive regarding the time requirement and laboratory facilities, while computational simulations demand the development of numerical models that, once validated, provide valuable tools for parameter optimization. In this work, experiments and simulations are performed based on the design of experiments to assess the effects of the parametric inputs on the resulting surface roughness and heat-affected zone depths. The data obtained are used to create both linear regression and artificial neural network models for each variable. The models with the best performance are then used in a multiobjective genetic algorithm optimization to establish combinations of parameters. The proposed approach successfully identifies an acceptable range of values for the given input parameters (laser power, focal offset, axial feed rate, number of repetitions, and scanning speed) to produce satisfactory values of Ra and HAZ simultaneously

Laser polishing of additively manufactured Ti-6Al-4V: Microstructure evolution and material properties

Laser polishing of metals consists of irradiating the part’s surface with a laser beam, thus generating a molten layer that is redistributed and resolidified to create a surface with reduced roughness. However, the process is also characterized by an instantaneously formation of heat-affected zones with consequent microstructural changes that influences the mechanical properties. In order to understand the microstructural evolution during laser polishing of Ti-6Al-4V laser-based powder bed fusion samples, a thermal model is applied in the current study to predict the dimensions of the melted zones and the heat-affected areas. Furthermore, the results obtained through the simulations are discussed and compared to the experimental data, thereby establishing the validity of the process models. Finally, the experimental studies also include the evaluation of the material hardness and residual stresses after laser polishing