laser solutions short courses · laser solutions short courses short course #4 ... 12_aido-3.ppt...

Laser Solutions Short Courses

Short Course #4

Laser Surface Treatment and Additive Manufacturing – Basics

and Application Examples

Ingomar Kelbassa Course Instructor

Wednesday, November 4 3:00PM

Room: Narcissus/Orange

1

Laser Surface Treatment and Additive Manufacturing – Basics and Application Examples

by

Akad. Rat Dr.-Ing. Ingomar Kelbassa

Academic and vice director LLTAcademic and vice director, LLT

Head of Experts Department, ILT

Phone: +49 241 8906 143

Email: [email protected]

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Laser Surface Treatment and Additive Manufacturing

Content • Laser Cleaning (LC)

• Laser Polishing (LP)

• Local Heat Treatment (LHT)

• Laser Metal Deposition (LMD)

• Selective Laser Melting (SLM)

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Content • Laser Cleaning (LC) Video





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Removal of surface layers with laser radiation

Advantages:

• cleaning of sensitive surfaces

• low thermal, mechanical andchemical load of the workpiece

• controllable removal

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• controllable removal

• abrasive free, chemical free andcontact free technique

• manual / automated technique

• low emission

• evaporation of the surface layer• removal by thermal induced stresses• removal by shock waves

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Cleaning/Removal with laser radiationabsorption heat conduction decomposition/ sublimation

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adaption of the wavelengthto the layer system• high absorptivity of the

surface layer AD

• low absorptivity of thebase layer AG

adaption of theinteraction time

• short interaction time ti→ short pulse duration→ high process rate

adaption of power density IL

• IL > ID (threshold ofsublimation/decomposition)

• EL > ED (binding energyof the surface layer)photo chemical removal

⇒ rule: short and intensive

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Laser sources

cw/pulsed

40 (cw) /4(8 -10 i.P.)

no

10.6

Characteristics

Wavelength [µm]

Output power [kW]

Fiber delivery

TEA

0,15 / 2

no

10.6

Nd:YAG

< 8

yes

1.06

≤ 1 10 W - 100 W< 15 W, < 5 W

yes (0,532)

0.532, 0.355,0.266

Up to 6

yes

0.8 - 1

0,02 - 0,3

no

0.157, 0.193, 0.248,0.308, 0.351

ExcimerDiodefrequencyconverted

Q-switchd.p.

cwd.p.

CO2

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50 (cw) /90

5 - 15

Costs [€/W] 130-300

5 - 10

90-170 90 - 350

10-20 8 - 16

1000 (0,532)

4 - 8, 1 - 4

40 - 70

25 - 35

1000 - 1500

≤ 1

0,1 -0,5ms

> 5

Pulse duration

Pulse frequency[kHz]

3 µs

0,1

50-1000 ns

0 - 50⎯

⎯ 10 - 50 ns

2 - 100

> 100 µs

10

10 - 25 ns

0,1 - 4

Efficiency [%]

3

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Processing strategies for surface cleaningmask image strategy scanning strategy

mirrormirror

mirror movablein y-axis

Δy

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mask

lens

workpiece workpiece

movablein x-axis

lens

vs

ΔyP

ΔxP

dW Δy

Δx=vs/fP

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Suction systems for the emission products

characteristics:

• emission rate• particle size distribution• chem. composition

global suctionsystem

localsuctionsystem activated

carbon filter

particle filter

pre filter

waste gas

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⇒

• hazard analysis• determination of

emission limit value

clean gas

high vacuumsuction system

carbon filter

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Cleaning with laser radiation - systems technology

manual cleaning automated cleaning

20 cm

• fiber-coupled solid state laserwith 500 Watt of output power

• automatic and mobile• integrated cooling system• compact domensions (B x T x H: mm)

of 1200 x 1150 x 1400: mm

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20 cm

Source: Clean Lasersysteme

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Processing Head for Manual Operation

Technology:

• Optical system for 500 W laser with up to 70mm deflection width

• Can-Bus controlled menu

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• Integrated air cooling and suction channels

• Light weight Aluminumhousing

• Weight: ~5 pounds


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Backpack Laser

• Battery powered backpack laser forsmall areas (20W only)

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Laser cleaning in precision and micro engineering

Requirements

• high precision of theremoved geometry

• removal of layers in the µm-range

• no damagespinning jets

Applications

source:SLCR

20 mm 50 µm

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no damageof substrate

• high degree ofpurity for following manufacturing steps

• quality controlBond-Pads

10 mm

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Laser cleaning in tool and mould making

Requirements

• minimal thermal andmechanical influenceof the base material

• often cleaning in assembled state →

Applications

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• mobile cleaning systems• avoidance of

residual layers• manual und automated

cleaning systems • vulcanization tools• die casting moulds

source: Clean Systeme100 mm

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Cleaning of a PUR - tool

Al tool for processingof polyurethan

Contamination: residuesfrom flame retardant

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• cleaning with Nd:YAG-Laser 500 W

• hand guided processinghead

Quelle: Clean-Lasersysteme

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Laser cleaning of big buildings and constructions

Requirements• high feed rates →• high powerlaser

sources• effective suction

system

Applications

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• often mobilecleaning systems

• high robustness• high compactness• easy to use for

manual operation

• facades, bridges, bulk containers, high voltage pylons• ships, airplanes, railed vehicles• big machine parts, cylinders

source: Quantel

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• Laser Polishing (LP) Video




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Deficits of conventional polishing for 3D parts

Vision:Manual polishing of 3D parts (e. g. injection moulds)

Disadvantages:• time consuming (approx. 25 min/cm2)• high costs

l d ibili

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• low reproducibility

--> High demand for automated polishingtechniques

--> Laser polishing (still under development)

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Process layout

Step 1:Remelting of a thin surface layer (10-100 µm) for smoothing macro roughness

laser radiationβ

vS

Scanning process:

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Step 2:Ablation and remelting of micro roughness

lS dyα

btrack

dL

1

1+2

milled surface

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Step 1: Remelting of a thin surface layer for smoothing macro roughness

cross section after step 1Results depend on

• Initial surface roughness

• Metallic and non metallic inclusions

HAZRD

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RD - Remelting depthHAZ - Heat affected zone

• Chemical composition -> influence on physical properties (e. g. melting point, viscosity)

• Homogeneity (rolled, casted)100µm

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Step 2: Ablation and remelting of micro roughness

tP = 16 nsstructure remains

high gloss level

tP = 480 nsstructure removedmedium gloss level

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Surface after step 1remaining structure

λ~15 µmlow gloss level

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Solid state laser sources

wavelength [nm]

mean laserpower [W]

pulse duration [ns]

pulse frequency [kHz]

CL120Q HPQL Slab80

1064 1064 1064

100 500 80

150 - 200 100 - 700 5- 20

8-50, cw 20-30, cw 0-40, cw

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fiber diameter [µm] 200 300 –

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Machine tool for laser polishing

• Base machine isa machining centerfrom Hermle

• Integration of- laser source- optics

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op cs- process gas system- control software

• Funded by BMBF inthe project „POLAR“

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Technical Data

Traverse paths for the axes X 600 mm, Y 450 mm, Z 450 mmB ±110°, C 360°

Process chamber for 350 x 350 x 200 mm³

Max. part weight 190 kg

Scan volume 190 x 190 x 70 mm³

L O ill t lifi Nd YVO l

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Laser source Oscillator-amplifier Nd:YVO4-laser 150 W (cw), 50 W (pulsed)

Pulse duration 10 bis 35 ns

Control system Siemens 840D, extended by scanner control,process gas control, laser power control

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RoughnessLathed

Laser polished

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Ra Rq Rz Rmax Pt WT tP(1µm)Lathed 3,89 µm 4,30 µm 15,1 µm 18,0 µm 18,3 µm 2,43 µm 11 %

Laser polished 0,18 µm 0,23 µm 1,07 µm 1,32 µm 1,60 µm 0,34 µm 72 %

Percentage change -95 % -95 % -93 % -93 % -91 % -86 % +61 %

p

Presently achievable roughness: from Ra = 1 - 2 µm to Ra = 0.1 - 0.3 µm

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Hardness

Material 1.2343, annealed, 250 HV

Remelted layer500-600 HV

Heat affected zone

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400 HV

0100200300400500600

0 50 100 150 200depth [µm]

hard

ness

[HV

0,01

]

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Cracks and pores

• Inspection of the remelted layer in a polished cross section with REM

• Dye penetrant inspection (EN/ISO 3452)

base material

remelted layer

50 µm polished area

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-->No cracks or pores detected

10 mm

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Tool and mould production

Material: 1.2343

Initial surface:milled, EDM

Results: fromRa = 1 -2 µm

to Ra = 0.14 -0.25 µm

Processing time: 1 - 3 min/cm²

1 mm

sharp-edges

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Processing time: 1 3 min/cm

100 mm

Side of the slider polished with laser radiation

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Polishing of structured surfaces

1 mm

polished | cauterised

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50 µm

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Task: Polishing of EDM processed surfaces

Material: 1.2343

Processing time: 17 s/cm²

Advantages:

EDM-processedsurface

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• removal of sharpedges and undercuts

• generation of graded shades and markings

• adjustable stucture by process parameters

after structure-polishing

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Moulds for glass production

Materials:1.2782, cast iron (GJS, GJL)

Problem:Cracks in the remelted layer

Initial roughness:milled, EDM, Ra = 1 - 3 µm

1 2782 EDM Ra = 3 0 µm

CastironGJL→

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Required roughness:Ra < 0.6 µm

State of R+D:1.2782 → Ra = 0.4 µmCast iron → Ra = 0.4 µmNo cracks

1.2782, EDM, Ra = 3.0 µm

1.2782, laser polished, Ra = 0.4 µm

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Porous materials

1 defects

21

2

Task:generation ofdefect-free surfaceson porous materials(e. g. investmentcasting, MIM)

Processing time:

Area 1mechanically ground

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2Processing time:10 s/cm² (laser)

Materials:titanium,stainless steel Area 2

polished with laser radiation+ mechanically ground

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Polishing of Implants

Materials:- Cobalt-Chromium-Alloys- Titanium - TiAl6V4

Roughness:- from Ra = 0,5 - 1,5 µm

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- to Ra = 0,09 - 0,3 µm

10 mm

10 mm

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Polishing of quartz glass with laser radiation

CO2-laser

Treatment of plane andund rotation-symmetric components

rougness Ra < 10 nm

Wechselwirkungszone

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1mm500nm

laser beam polished Ra <10 nm

grinded, Ra = 100 - 150 nm 20 mm

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Polishing of quartz glass with laser radiation

1mm

initial roughnessgrindedRa ≈ 100 nm

conventional polished Ra ≈ 1 3 nm

1,00

10,00

100,00

Ra [nm]

50 10 640320160804020 25601280

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laser beampolishedRa ≈ 13 nm

Ra ≈ 1,3 nm

0,01

0,10

λco [µm]50 10 640320160804020 25601280

Laser polishedmech. polishedInitial state

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Polishing of plastic material

Task:Elimination of scratchesfrom CD-surfaces

Laser source:CO2 (400W)

Material: Polycarbonate

scraped surface

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Material: Polycarbonate

Processing time: 25 s

Problem:Distortion by thermal induced stresses

polished surface

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Structuring by remelting

• Modulation of laser powergenerates structures

• Parameters are similar tothe polishing parameters dy

yz

x

remeltingtracks

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• Structures showa polished surface

PA

PM

λ

location

lase

r pow

er

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Structures

+25µm

-20µm

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2 mm

+25µm

-10µm

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Characteristics

• Lateral dimensions of the structures (λ): 100 µm - some mm

• Height of the structures (h):from 1 µm to some 100 µm, dependent on the lateral dimensions of the structures (λ)

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• New surface designs and functional surfaces

• Genearation of sloped flanks incomparision to chemical etching

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Laser Surface Treatment and Additive ManufacturingMotivation

Use of Ultra High Strength Steels (UHSS)

for car body components

Use of Ultra High Strength Steels (UHSS)

for car body components

Reduction in sheet thickness Reduction in sheet thickness

Weight savingWeight saving

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Weight saving Weight saving

Improved crash behaviour Improved crash behaviour

Increased safety Increased safety

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Restriction for the use of UHSSRestriction for the use of UHSS

High strength = low formability High strength = low formability

Restricted forming degreesRestricted forming degrees

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Restricted forming degrees Restricted forming degrees

Increased forming loadIncreased forming load

Increased tool wearIncreased tool wear

Increased springback Increased springback

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SolutionLocal heat treatment to improve formability

where high deformation degrees are required

SolutionLocal heat treatment to improve formability

where high deformation degrees are required

Increased formability Increased formability Extended applications Extended applications

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Decreased forming loadDecreased forming load

Decreased tool wearDecreased tool wear

Cost savings Cost savings

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UHS Steels are:

• Dual Phase steels (DP)

• Retained Austenite steels (RA)(former known as TRIP)

• Complex Phase steels (CP)

M i i l (MS)

UHS Steels are:

• Dual Phase steels (DP)

• Retained Austenite steels (RA)(former known as TRIP)

• Complex Phase steels (CP)

M i i l (MS)10

20

30

40

50

60

Form

abili

ty, A 8

0 (%

) Mild Steel

High Strength Low Alloyed Steel

Dual Phase Steel

MartentiticSteel

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• Martensitic steels (MS)• Martensitic steels (MS)0

200 400 600 800 1000 1200 1400Tensile strength, Rm (MPa)

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Laser Surface Treatment and Additive ManufacturingMaterials

Material Rolling condition

Microstructure Yield strength (MPa)

Tensile strength (MPa)

Elongation A80 (%) min.

DP 600 cold Ferrite + Martensite, (retained Austenite)

350-450 600-700 16

DP 1000 cold Ferrite + Martensite, (retained Austenite)

700-950 1000-1200 5

MS-W 1200 hot Martensite 950-1200 1200-1400 4 RA-W 700 hot Ferrite, retained

Austenite, Martensite 400-500 700-800 20

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Sheet thickness: 1.0 – 1.8 mm

Surface: not galvanised

Sheet thickness: 1.0 – 1.8 mm

Surface: not galvanised

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Laser Surface Treatment and Additive ManufacturingExperimental set-up

Principle of Laser Heat Treatment (LHT)

Laser beam

Main parameters:

• Laser power P

• Beam area A

• Velocity v

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Movement Clamping

x

zy

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Laser Surface Treatment and Additive ManufacturingExperimental set-up

Constant surface temperature due to temperature control during treatment

Constant surface temperature due to temperature control during treatment

laser power

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Temperature (set value)offset areaScanning

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Parameter variation: Set value = Surface temp.

Results and discussion

MSW 1200; d = 1,8 mm, v = 1 m/min

300

350

400

450

ness

[HV

0.3]

Hardness level of initial state: 434 ± 14 HV 0,3

Melting

MSW 1200; d = 1,8 mm, v = 1 m/min

300

350

400

450

ness

[HV

0.3]


Melting

Max. hardness reduction at set values around 1 V (T > AC3)

Max. hardness reduction at set values around 1 V (T > AC3)

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150

200

250

0 1 2 3 4 5 6 7 8Set Value U [V]

Har

dn

150

200

250

0 1 2 3 4 5 6 7 8Set Value U [V]

Har

dn

Selected range of set value

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MSW 1200; d = 1,8 mm; U = 1 V

300

350

400

450

dnes

s [H

V 0,

3]


PL = 3 kw (maximum)(no temperature control)

MSW 1200; d = 1,8 mm; U = 1 V

300

350

400

450

dnes

s [H

V 0,

3]


PL = 3 kw (maximum)(no temperature control)

Parameter variation: Velocity


No significant change in hardness with increasing velocity

No significant change in hardness with increasing velocity

Interaction time 1 s

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150

200

250

0 500 1000 1500 2000 2500 3000 3500Velocity v [mm/min]

Har

d

150

200

250

0 500 1000 1500 2000 2500 3000 3500Velocity v [mm/min]

Har

d

Selected velocityHigh velocity = high temp. gradients = increased distortion

High velocity = high temp. gradients = increased distortion

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10 µm

a b

10 µm

a b

Microstructure of MS-W 1200

a) Initial stateMartensite, Bainite and Ferrite420-430 HV0.1

b) LHT: Tbs ≈ 600 °C tempered Martensite, Bainite and Ferrite

a) Initial stateMartensite, Bainite and Ferrite420-430 HV0.1

b) LHT: Tbs ≈ 600 °C tempered Martensite, Bainite and Ferrite


F

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c d c d

Bainite and Ferrite350-380 HV0.1

c) LHT: Tbs ≈ 700 °C Martensite + Ferrite 260-280 HV0.1

Bainite and Ferrite350-380 HV0.1

c) LHT: Tbs ≈ 700 °C Martensite + Ferrite 260-280 HV0.1

d) LHT: Tbs ≈ 800 °CMartensite, Ferrite + Bainite 260-280 HV0.1

d) LHT: Tbs ≈ 800 °CMartensite, Ferrite + Bainite 260-280 HV0.1

M

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Mock-up geometry

“Hat profile”

Mock-up geometry

“Hat profile”


Deep drawing tests

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Projection of tracks to be laser heat treated

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Calculated slide forces for MS-W 1200Calculated slide forces for MS-W 1200


Deep drawing tests

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Initial state LHT

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Reduced sliding forces during deep drawing achieved (MS-W 1200)Reduced sliding forces during deep drawing achieved (MS-W 1200)


Deep drawing tests

505 mm

75 m

m

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Laser heat treated sheet Deep drawn hat profile

2

Initial: F = 1300 kN (draw depth 40 mm) LHT: 1020 kN, reduction of 22 %Initial: F = 1300 kN (draw depth 40 mm) LHT: 1020 kN, reduction of 22 %

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Hardening with Laser Radiation

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Advantages:• local adapted low heat input• low warpage• high automation level

Advantages:• local adapted low heat input• low warpage• high automation level

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Hardening with Laser radiation(Temperature-time-cycle and corresponding transformation of microstructure)

1) Heating:(α-γ-transformation; formation of austenite)

2) Minimum holding time:

1) Heating:(α-γ-transformation; formation of austenite)

2) Minimum holding time:

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) g(diffusion of carbon into iron crystal)

3) Cooling :(formation of martensite)

) g(diffusion of carbon into iron crystal)

3) Cooling :(formation of martensite)

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Hardening with laser radiation(TTA(1)-diagram for Ck 45)

Temperature of austenitization depends on:• heating rate

(Laser: ca. 300…3000°C/s)

Temperature of austenitization depends on:• heating rate

(Laser: ca. 300…3000°C/s)

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• carbon content• alloying elements• carbon content• alloying elements

(1) TTA: time-temperature-austenitization

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Process layout of hardening with laser radiation

Required hardening geometry

Process monitoringMultipleAdaptation of theAdaptation of the

Model Experiment

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Process monitoringpbeam technique

pintensity distribution

pprocess parameters

without process control

with process control

• Laser power• Intensity distribution• Angle of incidence• Beam geometry• Velocity

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Temperature control on example geometries

a) Scheme (cross section) c) Temperature signal (uncontrolled/controlled)

uncontrolled

Laser-beam

Feed direction

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Seite 58

controlled

uncontrolled

b) Hardening track (top view)

controlled

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Hardening of cylinder-liners of diesel locomotives

b) Set-up

Aim: reduction of the abrasion of cylinder-liners under operating conditionsAim: reduction of the abrasion of cylinder-liners under operating conditions

a) Scheme

laser beamoptics

cylinderøi=240nm cylinder

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glass fiberøi=0.6mm

optics

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Result: generation of different hardening geometries(hardening length lH =400mm; hardening width wH =8 and 10mm)

Result: generation of different hardening geometries(hardening length lH =400mm; hardening width wH =8 and 10mm)

Test procedure

• Abrasion tests at plane specimen: o.k.

Hardening of cylinder-liners of diesel locomotives

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• Deviation of the roundness of hardendcylinder-liners: 10 - 30 µm(state of delivery: 0 - 20 µm)

• Run time tests in locomotives (1/2 year): in test

5 cm

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Aim: reduction of the abrasion of piston-rings under operating conditionsResult: hardening width wH ≈ 5 mm; hardening depth dH ≈ 0,35 mmAim: reduction of the abrasion of piston-rings under operating conditionsResult: hardening width wH ≈ 5 mm; hardening depth dH ≈ 0,35 mm

Hardening of piston-ring slots

angle of incidence

hardeningdepth dh

beam position

g

aB

b) Piston head c) Cross-sectiona) Scheme

piston ring slots crosssection

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processingspeed vhardening

geometry

hard

enin

gw

idth

wh

slot

dept

hd s

piston

section

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Laser Surface Treatment and Additive ManufacturingHardening of torsion springs(Modules)

10 mm

hardening processexhaustion pyrometer laser source

b:\a

23\1

998\

fest

phas

e\FE

P_H

AE05

9.jp

g

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b:\a23\1999\festphase\FEP_HAE075.jpg

handling system clamping device

10 mm

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Correlation between temperature signal and hardening depth

Mean values:

Hardness depth at position 0°:0,2 mm...0,4 mm

Process window: “o.k.“ -hardening

3,20

3,40

3,60

ge1+

Uav

erag

e2)/2

[V]

melt ing guide" n.o.k.

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, ,

Temperature signal:2,96 V...3,27 V

2,60

2,80

3,00

0 0,1 0,2 0,3 0,4 0,5 0,6 0,7hardening depth LHT(0°) [mm]

T.-s

igna

l (U

aver

ag " o.k.

" n.o.k."

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Hardening result n.o.k. o.k. n.io.Ok.

Hardness depth < 0,2mm 0,2mm ... 0,4mm > 0,4mm

Correlation between temperature signal and hardening depth

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Peak value <2,98V 2,98V...3,35V >3,35V

Mean value <2,96V 2,96V...3,35V >3,35V B.\a23\2003\festphase\WI_0310-kztuh.DOC

FEP_HAE065.JPG FEP_HAE064.JPG FEP_HAE081.JPG 2mm2mm2mm

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Hardening of linear guiding rails

Problem: warpage in conventional treatment ⇒ many post treatment stepsAim: simultaneous treatment of all ball bearing tracks (minimized warpage)Result: warpage ≤ 0,3 mm/m ( state of delivery)

Problem: warpage in conventional treatment ⇒ many post treatment stepsAim: simultaneous treatment of all ball bearing tracks (minimized warpage)Result: warpage ≤ 0,3 mm/m ( state of delivery)

a) Multiple beam techniquewith temperature controll

Linear guiding railINA Schaeffer KG© b) Cross section

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(586)

2 mm

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• Laser Metal Deposition (LMD) Video


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LMD with powder feeding – “1 step process”

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LMD expertiseHandling /powderfeeding components

Process management Materials

100µm

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Process monitoringLaser sources Process modeling

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Principles of powder feeding

continuous powder feeding discrete powder feeding

coaxial powder feeding

optics

off axis powder feeding

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Concepts for powder feeding nozzles

continousoff-axis discrete

coaxial

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10 mm

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LMD head for cladding inner contours

Guide Tube

IBO Module IV:Support for guide tube

IBO Module III:Fibre connector support

Fibre connector

IBO Module II:Optic

IBO Module I:Head

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(Light fibre)Head

Optic and protection glass

Outer diameter: 22 mm

Length: 102 mm

2 internal cooling cycles, powder supply, shielding gas supply

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Zoom optic for variable track width

• Solid state and diode lasers

• CNC controlled

• Laser power up to 3 kW

• Variable tracks widths approx. 0,6 mm – 4 mm

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50 mm

• Constant tool centre point

• 3D-cladding possible

• Up to 90 degrees inclination possible

In cooperation with Reis Lasertec

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NGV 2 (+ Liner 1)LMD for Cladding of mesh structures, In 625 on Mar-M 002 (+ CMSX-4)

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NGV 2 with cladded mesh structures (ILT / LLT) and TBC applied by APS (FZ Jülich)

Liner 1 with cladded mesh structures

• Feasibility study incl. determination of suitable process layout and process parameters finished 4 years ago

• Now: Manufacture of OEM parts

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Reconditioning of damping wire grooves by LMD / Ti-6246Laser cladded grooveFront drum

Before / after cladding

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Main challenges:• Accessibility• Processing without affecting opposite wall

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Tip & Leading Edge BLISK repair by LMD / Ti-17 / Ti-6Al-4V

By laser cladding reconditioned BLISK-blade tip

By laser cladding repaired BLISK-blade leading edge

By laser cladding reconditioned BLISK-blade leading edge

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By laser cladding reconditioned BLISK-blade tip10 mm

10 mm

26

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Laser cladding of glass moulds

Materials:

• Glass mould: grey cast iron• Layer: Ni-Base alloy

Processing:

• fiber coupled diode laser P = 2 kW

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diode laser PL = 2 kW• 3D-cladding with

discrete 3 -beam nozzle• Processing time for

typical glass mould:5 -10 minutes

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LMD of copper mould insert

50

100

150

200

250

300

350

400

450

500

Här

te [H

V 0,

3]

layer substrate

Har

dnes

s [H

V 0

.3]

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77

Surface hardness up to 450 HV

FeCrV

FeNi Intermediate layer : FeNi

Graded layer: FeCr + FeCrV

FeCr

Cu 500 µm

00,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6

Abstand von der Oberfläche x [mm]distance from surface [mm]

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µ-LMDCross section

Top view

• Substrate: 1.4403 (stainless steel)• Additive material 316L: 1.4404• Powder particle diameter: 1-9 µm

Result:• Homogenous track geometry• Track width: ≈ 50 µm• Track height: ≈ 7 µm

P= 14 Wv= 500 mm/minØL= 60 µm

substrate

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Top view • Track height: ≈ 7 µm• Melting depth: ≈ 6 µm

High dilution: > 40%

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µ-LMD: Potential applicationsMedical Science Electronic Industry Energy Sector

SEM

F A i d200 µm

4 mm

Electronic switch

Fa. Inovan GmbH

Silver contact

50 µm1 mm

Gold contacts Cross section

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• Increasing X-ray visibility by cladding markers made of tantalum on nitinol stents

• Selective cladding of silver contacts on stainless steel switchesReduction of used precious material

• Gold contacts for fuel cells

Fa. Angiomed µ

X-ray 2 mm

FZ Jülich

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Repair of HPT Case at several locations

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300 mm

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Machine implemented at Rolls-Royce, Oberursel

• 1 kW lamp pumped Nd:YAG laser

• 5 + 2 axis (turning table)

• Automated powder

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mass flow measurement

• Automated laser power and beam profile measurement(PRIMES)

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Cladding of aero engine components at KLM, Amsterdam

Repair of flangeand cross section

Repair of sealingand cross section

Examples: housing flange (Inconel 718), rotating seals (17-4PH)

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Seite 82In cooperation with KLM

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Cladding of aero engine components at KLM, Amsterdam

• 6 Axes Stäubli Robot+ turning table (tiltable)+ long turning table

• 1 kW fibre coupledNd:YAG laser

• Completely automated

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• Sensing system fordetecting position of components

In cooperation with Rolan Robotics

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Laser cladding of gear components at Stork Gears &Services, Rotterdam

Applications

• Petrochemical industry /offshore drilling

• Shipping

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• Storage and transhipment

• Sugar industry

• Steel industry

• Energy companiesSource: Stork Gears & Services

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• 2 kW fibre coupled diode laser from Laserline

• Discrete coaxial nozzle

• Turning table

• Robot system

Typical layer thickness 0 5 mm

Repair of gear components at Stork Gears & Services

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• Typical layer thickness 0,5 mm

• Hardness 36 - 62 HRC

Replacement of:

• Chromium plating

• Thermal sprayingIn cooperation with Stork Gears & Services

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• Selective Laser Melting (SLM) Video

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SLM – powder bed based “2 step process”

melting ofthe powder

application ofpowder layer

3D-CAD model subdivided into layers

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metal powderlowering the platform

metal part madeof serial material

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Characteristics of LMD and SLM

SLMLMDcharacteristics

materials large materialsdiversity

• limited and lowerexperience incomparison to LMD

limited by thehandling system

limited by theprocess chamber

(ø : 250 mm, height : 160 mm)part dimensions

limited nearly unlimitedpart complexity

Selective Laser Melting (SLM)

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≥ 0.1 mm ≥ 0.1 mmdimensional accuracy

• 3D-surface• on existing parts

• flat surface• flat preformsbuild-up on

10 - 40 cm3/h 2 - 10 cm3/hbuild-up rate

60 - 100 µm 30 - 50 µmroughness Rz

≥ 0.03 - 1 mm ≥ 0.03 - 0.1 mmlayer thickness

Laser Metal Deposition

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Individual parts and small lot series by SLM

• Application:manufacturing of internal hollow structures

• Advantage:no geometric limitations like conventional

TiAl6V4 AlSi10Mg

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like conventional

• Vision: ultralight structures incombination with light weight materials like Ti-6Al-4V (aerospace appl.)

Inconel 718

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Mould inserts with Conformal Cooling

• Application:Design of conformal cooling channels

• Advantage:• Time reduction during

i j ti ldi

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in cooperationwith BRAUN GmbH

injection moulding• Quality enhancement through

reduction of warpage

• Vision:Manufacturing of inserts for „critical“ points in tools

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• Application:Manufacturing ofinserts on top of preformsmade of tool steel

• Results:


in cooperationwith BRAUN GmbH

Hardness53 HRC49 HRC56 HRC

preform

SLM part of insert

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Results:• Continous high hardness

of 52 HRC• Small heat affected zone• No cracking in SLM

part and interface

preform

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Thermographic image after 2sec. CoolingResults: • Significantly higher

cooling rate of SLM partin comparison to copper

SLM part

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alloy

• Improvement of plastic part quality through homogeneous tem-perature distribution in the mould

Ampco 940

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SLM of ceramics

Ceramic materials

Zirconium-based ceramicsDensity approx. 100%First demonstration parts manufactured

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Current R&D-focus:Avoidance of micro-cracks

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SLM of PEEK

PEEK

Density ca. 100%

First demonstration parts manufactured

Current R&D-focus:

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Current R&D-focus:

Development of machine components

Reproducibility

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µ-SLM

dCyl

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d Hol

e

Using reduced powder grain sizes in combination with novel fibrelasers with high beam quality elemental structure resolution of:

dCyl = 180 µm, dHole = 100 µm could be achieved

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Combination of additive and ablative techniques

Tool for micro injection moulding• preform conventional manufactured• generative process including cooling

channels by SLM• post processing:

– outer control: grindig– inner control: laser ablation

final partSLM-partpreform

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First Industrial Application of SLM - Dental Restaurations

• Application:reconstructionof single teeth

• Process steps:– preparation – model

digitalization

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– digitalization– design (CAD)– manufacturing (DLF)– control of model– ceramic cover

• Production start:Nov. 2002 In cooperation with BEGOmedical AG

Thank you very much for paying attention!

Contact

Akad. Rat Dr.-Ing. Ingomar Kelbassa

Academic and vice director LLTAcademic and vice director, LLT

Head of Experts Department, ILT

Phone: +49 241 8906 143

Email: [email protected]

ICALEO® 2009 Laser Solutions Short Course Evaluation

Course #4: Laser Surface Treatment and Additive Manufacturing – Basics and Application Examples Course Instructor: Ingomar Kelbassa Please rate the following: (circle) Very Course Excellent Good Good Fair Poor Overall Course 5 4 3 2 1 Course Instructor 5 4 3 2 1 Presentation of material 5 4 3 2 1 Organization of material 5 4 3 2 1 Course well paced 5 4 3 2 1 Would you recommend this course to others in your profession? yes no

What was the strongest feature of the course? What was not covered that you felt should have been covered (if anything)? What would you like to hear more about next time? What was covered that left an impression/impact on you? Suggestions & Comments (for this course or courses you would like in the future): Name: (optional)

Please Use Reverse Side for Additional Comments.

Please return evaluation form to the Registration Desk by Thursday afternoon

or fax 407.380.5588 to LIA upon your return home.

THANK YOU!

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