Workshop Process Monitoring and Process Control in Additive Manufacturing

Friday March 26th 2021


Agenda

 

1 p.m. – 1.05 p.m.

Dr. Torsten Hermanns
EurA AG

Welcome

1.05 p.m. – 1.35 p.m.

Talu Ünal-Saewe
Fraunhofer ILT
Aachen Germany

Extreme High-speed Laser Material Deposition for Coating, Repair and Additive Manufacturing

1.35 p.m. –2.05 p.m.

Rodrigo Linares
New Infrared Technologies Madrid Spain

Innovative solutions based in high-speed infrared imaging for QA of metal 3D printing processes

2.05 p.m. –2.35 p.m.

Stefan Mann
Fraunhofer ILT

Aachen Germany

System technology for ensuring process stability in DED-LB

2.35. p.m. – 3.05 p.m.

Felix Fischer
Fraunhofer ILT

Aachen Germany

Optical process monitoring in Laser Powder Bed Fusion

3.05 p.m.

Open discussion

 


Each presentation will be 15 – 20 minutes followed by 10 minutes discussion


Abstracts

Extreme High-speed Laser Material Deposition for Coating, Repair and Additive Manufacturing

Talu Ünal-Saewe

Fraunhofer ILT

 

Extreme high-speed laser material deposition, known by its German acronym EHLA, is a new, highly productive variant of laser material deposition. With EHLA thin metal layers can be applied to almost any metallic base material in a very short time and in a resource-efficient manner. It eliminates coating processes' shortcomings, in particular hard chrome plating and thermal spraying, providing an eco-friendly and economical alternative. In many applications, it is a viable substitute for hard chrome plating with chromium (VI), which has been subject to rigorous constraints in the EU since September 2017. This process also has great potential in the rapidly growing additive manufacturing market, particularly for the modification of the geometry of large components. Fraunhofer Institute for Laser Technology (ILT) developed the basis for EHLA and established the process in industrial manufacturing in a joint interdisciplinary effort with machine manufacturers and end users. The talk covers the presentation of the basic technological principle as well as possible fields of application.


Innovative solutions based in high-speed infrared imaging for QA of metal 3D printing processes

Rodrigo Linares

New Infrared Technologies

In preparation.

 


System technology for ensuring process stability in DED-LB

Stefan Mann

Fraunhofer ILT

 

The quality of additive manufactured components and coatings produced by Directed Energy Deposition-Laser Beam (DED-LB) is highly dependent on reproducible setups and process stability. High performance parts can only be manufactured free of defects in a defined process window. Small deviations already change the process result. For this reason, there is a great demand to control as well as to document process variables and to monitor the process itself. The talk introduces system technology developed by Fraunhofer ILT, that covers important requirements in quality assurance for DED-LB. It covers capabilities in supporting and documenting the process setup as well as monitoring the thermal emissions of the process and controlling the process stability. An important feature is the measurement of the entire powder gas jet. In DED-LB, the powder feed into the melt pool is of crucial importance. It has a decisive influence on the dimensional accuracy and the quality of the applied layers as well as the cost-effectiveness of the process.

 


Optical process monitoring in Laser Powder Bed Fusion

Felix Fischer

Fraunhofer ILT

To start the talk, a brief overview over the process monitoring capabilities for Laser Powder Bed Fusion (LPBF) at Fraunhofer ILT is given. Those include the observation of thermal signatures (e.g. pyrometers, IR-cameras, Optical Tomography), the vibrational behavior (e.g. ultrasound, air microphones) and of visible properties of LPBF-produced samples and of the process area. Two approaches that leverage recent advances from the area of digital image processing are introduced in greater detail. The first is a line-sensor based system that can be used to acquire highly resolving images of the solidified material and of the powder bed during the recoating process. Those images could be used to reconstruct the part geometry and detect deviations from the intended shape. The second system is comprised of regular area scan cameras. It is shown how those can be used to monitor the shielding gas flow and to estimate the impact of the laser-fume interaction on part quality.