Photonics: the discipline that is making manufacturing smart

Institute for Applied Laser, Photonics and Surface Technologies ALPS, Fiber Technology Laboratory

Dr. Valerio Romano, Professor for Photonics

Overview

• Short information on "Photonics" MSE Master

• Some thoughts on "smartness"• Examples of devices that might be used to implement

smartness in laser based machines

Introduction

• 2018: important year for photonics in Switzerland:• Industry has given strong signals of commitment towards

photonics as a key enabling technology ALSO in Switzerland• teaching (MSE Master is being prepared as a profile and will

start in 2020• profile description is ready; implementation in a course of study will

start in January 2019

• Manufacturing technologies impulse programme

• This workshop:• Thinking about how photonics impacts on manufacturing• How photonics can be implemented in industry by projects,

research and teaching• How to find a sustainable and effective implementation in

funding

Info: MSE Master Profile Photonics

• Profile description is in course of formulation and verywell on track

• 6 of 7 UAS participating• Early 2019 the modules wil be formulated• The contents discussed (not objected by anybody) are:

• Photonics for machining and manufacturing• Optical measuring• Optoelectronics and Electrooptics• Photonic systems (including design and simulation)• Manufacturing for photonics

• Planned start in fall 2020 (inscriptions 2019)

Photonics and noble prizes...

Schores AlfjorowHerbert Kroemer

Jack Kilby

Roy Jay Glauber

John Lewis Hall

Theodor Hänsch

Charles Kuen Kao

Willard Boyle

George Elwood Smith

Andre Geim

Konstantin Novoselov

Serge HarocheDavid Wineland

Isamu Akasaki

Hiroshi Amano

Shuji NakamuraArthur Ashkin

Gérard Mourou

Donna Strickland

2014

2018 Laserphysik

Manipulation von Quantensystemen

Blaue dioden

2009

opt. Glasfaser

„für die Erfindung des CCD-Sensors“

2010 Graphen

2012

2000Optoelektronik

Entwicklung des integrierten Schaltkreises

2005

optical coherence

opt. Spektroskopie, Frequenzkamm

2018

Tabelle1

2000Schores AlfjorowOptoelektronik

Herbert Kroemer

Jack KilbyEntwicklung des integrierten Schaltkreises

2005Roy Jay Glauberoptical coherence

John Lewis Hallopt. Spektroskopie, Frequenzkamm

Theodor Hänsch

2009Charles Kuen Kaoopt. Glasfaser

Willard Boyle„für die Erfindung des CCD-Sensors“

George Elwood Smith

2010Andre GeimGraphen

Konstantin Novoselov

2012Serge HarocheManipulation von Quantensystemen

David Wineland

2014Isamu AkasakiBlaue Dioden

Hiroshi Amano

Shuji Nakamura

2018Arthur AshkinLaserphysik

Gérard Mourou

Donna Strickland

2000Schores AlfjorowOptoelektronik

Herbert Kroemer

Jack KilbyEntwicklung des integrierten Schaltkreises

2005Roy Jay Glauberoptical coherence

John Lewis Hallopt. Spektroskopie, Frequenzkamm

Theodor Hänsch

2009Charles Kuen Kaoopt. Glasfaser

Willard Boyle„für die Erfindung des CCD-Sensors“

George Elwood Smith

2010Andre GeimGraphen

Konstantin Novoselov

2012Serge HarocheManipulation von Quantensystemen

David Wineland

2014Isamu AkasakiBlaue dioden

Hiroshi Amano

Shuji Nakamura

2018Arthur AshkinLaserphysik

Gérard Mourou

Donna Strickland

https://de.wikipedia.org/wiki/Schores_Iwanowitsch_Alfjorowhttps://de.wikipedia.org/wiki/Charles_Kuen_Kaohttps://de.wikipedia.org/wiki/Faseroptikhttps://de.wikipedia.org/wiki/Willard_Boylehttps://de.wikipedia.org/wiki/CCD-Sensorhttps://de.wikipedia.org/wiki/George_Elwood_Smithhttps://de.wikipedia.org/wiki/Andre_Geimhttps://de.wikipedia.org/wiki/Graphenhttps://de.wikipedia.org/wiki/Konstantin_Novoselovhttps://de.wikipedia.org/wiki/Serge_Harochehttps://de.wikipedia.org/wiki/David_Winelandhttps://de.wikipedia.org/wiki/Herbert_Kroemerhttps://de.wikipedia.org/wiki/Isamu_Akasakihttps://de.wikipedia.org/wiki/Leuchtdiodehttps://de.wikipedia.org/wiki/Hiroshi_Amanohttps://de.wikipedia.org/wiki/Shuji_Nakamurahttps://de.wikipedia.org/wiki/Arthur_Ashkinhttps://de.wikipedia.org/wiki/G%C3%A9rard_Mourouhttps://de.wikipedia.org/wiki/Donna_Stricklandhttps://de.wikipedia.org/wiki/Laserhttps://de.wikipedia.org/wiki/Schores_Iwanowitsch_Alfjorowhttps://de.wikipedia.org/wiki/Herbert_Kroemerhttps://de.wikipedia.org/wiki/Jack_Kilbyhttps://de.wikipedia.org/wiki/Jack_Kilbyhttps://de.wikipedia.org/wiki/Integrierter_Schaltkreishttps://de.wikipedia.org/wiki/Roy_Jay_Glauberhttps://de.wikipedia.org/wiki/Koh%C3%A4renz_(Physik)https://de.wikipedia.org/wiki/John_Lewis_Hallhttps://de.wikipedia.org/wiki/Frequenzkammhttps://de.wikipedia.org/wiki/Theodor_H%C3%A4nschhttps://de.wikipedia.org/wiki/Charles_Kuen_Kaohttps://de.wikipedia.org/wiki/Faseroptikhttps://de.wikipedia.org/wiki/Willard_Boylehttps://de.wikipedia.org/wiki/Integrierter_Schaltkreishttps://de.wikipedia.org/wiki/CCD-Sensorhttps://de.wikipedia.org/wiki/George_Elwood_Smithhttps://de.wikipedia.org/wiki/Andre_Geimhttps://de.wikipedia.org/wiki/Graphenhttps://de.wikipedia.org/wiki/Konstantin_Novoselovhttps://de.wikipedia.org/wiki/Serge_Harochehttps://de.wikipedia.org/wiki/David_Winelandhttps://de.wikipedia.org/wiki/Isamu_Akasakihttps://de.wikipedia.org/wiki/Hiroshi_Amanohttps://de.wikipedia.org/wiki/Shuji_Nakamurahttps://de.wikipedia.org/wiki/Roy_Jay_Glauberhttps://de.wikipedia.org/wiki/Arthur_Ashkinhttps://de.wikipedia.org/wiki/G%C3%A9rard_Mourouhttps://de.wikipedia.org/wiki/Donna_Stricklandhttps://de.wikipedia.org/wiki/Laserhttps://de.wikipedia.org/wiki/Koh%C3%A4renz_(Physik)https://de.wikipedia.org/wiki/John_Lewis_Hallhttps://de.wikipedia.org/wiki/Frequenzkammhttps://de.wikipedia.org/wiki/Theodor_H%C3%A4nsch

Lasers in production: one tool – many applications

Virtual factory

• Virtual factory• Task: create a factory to produce a symbolic object (Einstein)• Solution:

Data reshapingin our office

Artwork byRobley Browne

On «Bundesplatz»

What does "smart" mean (for a machine or a process)?• Some people see spiritual aspects behind

intelligence and smartness...

• No philosophical discussion on intelligence here.

• There is no such thing as an "error-free" process• In a manufacturing process, "smart" might mean to make a process

"autonomous", versatile, error tolerant and self repairing. This involves:• Fast data collection, very fast data transmission, ultrafast data analysis and

feedback;• digital storage of the process status;• taking repairing measures• resuming the process

• So "smart" might mean "Being able to collect big amounts of data veryquickly, transferring and analysing them and giving feedback in real time".

Powder characterisation

Determination of the heat conductivity of a powderby a laser probe beam.

Optical determination of the laser penetration depthas a function of densification and granulometryof a metallic powder.

Projektarbeit «Pulvercharakterisierung» (PA1) Christian Marti, FS 2016

A. Streek, HS Mittweida

Also possible from backscattered dataduring the process

Example: Surface inspection of powder bedProject work «Visuelle Überwachung des SLM Prozesses» (PA1) Matthias Fontanellaz, FS 2016

Shadows from obliquely incident light

Schatten-Differenzbild Binarisiertes Bild zur Höhenberechnung

Performance Mapping of the complete SLM chamber with 50µm resolution Min. detection heigth: 300µm Höhe (limited by computer

capacity) Measurement uncertainty: 23µm

Detection of delamination

Real-time 2D Quotient pyrometry for SLM process

• Temperatures can be measuredat wavelengths that are transmittedby the process optics

• 2D thermal maps in real-time

• High data rate needed

• Wireless?

SLM real-time thermal process inspectionBachelor Thesis «Real-time Überwachung des SLM Prozesses» H. Hodak & A. Keller, FS 2016Master Project work (EVA) Marco Jordi, 2017

Y.S. Lee / W. Zhang, 2015

▶ Mapping of the temperature distribution in and around the melt pool during laserirradiation

▶ Detection of instabilities in the melt pool

Multi-beam delivery through HC fibers

Cregan et al., Science 285, p. 1537, (1999) P.J. Roberts et al., Opt. Express 13, p. 236 (2005)

Photonic bandgap fibre• Ultralow loss

(~1 dB/km demonstrated)• ~100 nm transmission

window

Benabid et al., Science 298, p. 399, (2002)

Kagomé fibre• Higher loss

(~0.1-1 dB/m typical)• ~1000 nm transmission

window

Debord et al., Opt. Lett. 39 (21), p. 6245, (2014)

“Single-ring fibre”• Ease of fabrication• Simple structure to model• Losses and transmission

windows comparable to best kagomé fibres

Pryamikov et al., Opt. Express 19(2), p. 1441, (2011)

Delivering laser radiation in a wide range of wavelengths (UV - NIR) pulselengths (CW - femtoseconds)

through the same fiber.

Using the same fiber for the diagnostic signal

New generation of hollow core fibers

Potential benefits of "smartness" in laser based manufacturing

• Self-correcting processes• Product-adapted process parameters• High energy effectivness

SLS part produced in a collaboration between EPFL/IAP (Ø15mm) Ø15mm, 200 25µm layers

P = 1.4W, f=2kHz,v=40mm/s

Continuous wave interaction:3 watts average power

Near infrared pulsed laser sintering : Experiments Slide 16

Higher quality at lower power...

Pulsed interaction2 watts average power

100 µm

1 mm1 mm

100 µm

1 mm

Sintered with Nd:YAG,

195 mW average power (critical)

150 ps pulses, 80 MHz

Sintered with Nd:YAG,

275 mW average power

150 ps pulses, 80 MHz

Consolidation of nanopowder with ps-pulses

Summary• In connection with laser based manufacturing "smart"

means not only optimizing processes themselves but also continuously monitoring them and generating feedbackin real-time

• Photonics offers a wide range of tools to do that and in connection with digital data methods it can do itintelligenty.

• Fast transmission and processing of BIG amounts of digital data is necessary to implement "smartness"

Thank you for your attention

Photonics: the discipline that is making �manufacturing smartOverviewIntroductionInfo: MSE Master Profile Photonics Photonics and noble prizes...Lasers in production: one tool – many applicationsVirtual factoryWhat does "smart" mean (for a machine or a process)?Powder characterisationExample: Surface inspection of powder bedReal-time 2D Quotient pyrometry for SLM processSLM real-time thermal process inspectionMulti-beam delivery through HC fibersNew generation of hollow core fibersPotential benefits of "smartness" in laser based manufacturingHigher quality at lower power...Consolidation of nanopowder with ps-pulsesFoliennummer 18