The Experts below are selected from a list of 3207 Experts worldwide ranked by ideXlab platform

Eckhard Beyer - One of the best experts on this subject based on the ideXlab platform.

  • Surface Functionalization by High‐precision Laser Cladding
    Laser Technik Journal, 2013
    Co-Authors: Frank Brückner, Steffen Nowotny, Mirko Riede, Frank Kubisch, Christoph Leyens, Eckhard Beyer
    Abstract:

    Meanwhile the laser build-up welding technology is a well industrially established technique for highly precise coating tasks and additive manufacturing. By means of new precise Powder Nozzle systems, modified process equipment as well as suited manufacturing strategies, the generation of customized components can be realized up to a detail resolution within the double-digit micrometer range. This opens a variety of new applications, e. g. in aviation, tooling industry or medical technology.

  • Laser-based generation of precise functional structures and components
    International Congress on Applications of Lasers & Electro-Optics, 2013
    Co-Authors: Frank Brueckner, Steffen Nowotny, Mirko Riede, Christoph Leyens, Thomas Finaske, Eckhard Beyer
    Abstract:

    Functionalization of surfaces as well as the precise generation of metallic components are increasingly required in specific applications, especially in aviation, medical technology and micro tooling industry. The utilization of such parts is not only combined with beneficial properties including, for example, almost no porosity or cracking even on complex shaped parts, but also high flexibility and high robustness in processing. Some applications even require rapid adaptations of the generated geometry, e. g. to satisfy personal requirements of patients in the area of medical parts.By means of strongly reduced melt pool dimensions the generation of miniaturized structures and components can be realized up to a detail resolution within the double-digit micrometer range. This can be reached by the use of suitable laser sources (e. g. fiber and disc lasers). It also requires the implementation of precise Powder Nozzle systems, modified process equipment and new coating strategies supported by CAD/CAM interfaces. High precision laser cladding yields small heat affected zones and improved near-net shape contours. The interaction of complementary equipment permits a good reproducibility, but typically a rather low deposition rate.The comparison with high productive laser cladding which is characterized by deposition rates up to 15 kg/h shows the huge variability of this process. Hence, there is almost an order of magnitude of three between the smallest and the largest laser cladded weld bead track.Functionalization of surfaces as well as the precise generation of metallic components are increasingly required in specific applications, especially in aviation, medical technology and micro tooling industry. The utilization of such parts is not only combined with beneficial properties including, for example, almost no porosity or cracking even on complex shaped parts, but also high flexibility and high robustness in processing. Some applications even require rapid adaptations of the generated geometry, e. g. to satisfy personal requirements of patients in the area of medical parts.By means of strongly reduced melt pool dimensions the generation of miniaturized structures and components can be realized up to a detail resolution within the double-digit micrometer range. This can be reached by the use of suitable laser sources (e. g. fiber and disc lasers). It also requires the implementation of precise Powder Nozzle systems, modified process equipment and new coating strategies supported by CAD/CAM interf...

  • COAXID – omni-directional inner diameter laser cladding optic
    International Congress on Applications of Lasers & Electro-Optics, 2011
    Co-Authors: Frank Kubisch, Steffen Nowotny, Eckhard Beyer, Christoph Leyens, Anja Techel
    Abstract:

    Laser ID materials deposition is applied for inner surface coatings of abrasively loaded tools, the generative fabrication of inner 3D structures of aero engines and gas turbines as well as the repair of local damages in oil drilling tools. The core element of the modularly designed ID cladding head presented here is a multi-jet coaxial Powder Nozzle. This Nozzle concept permits a precise Powder supply in any welding position, independently from gravity and welding direction. Thus, not only simple inner coatings are applicable, but also complex shaped metal structures can be generated in internal areas with restricted accessibility. All media supply, such as Powder, shielding gas, cooling water, is safely packaged inside the processing head. The optical elements for shaping and focusing the laser beam are interchangeable and permit the use of disc an d Nd:YAG laser up to 3 kW laser power. Currently, the minimum ID caliber is 4 inches, and the maximum immersion depth amounts to 40 inches. Current developments aim at the reduction of the minimum diameter to 2 inches and increased immersion depths to more than one meter by using diode laser with high power.Laser ID materials deposition is applied for inner surface coatings of abrasively loaded tools, the generative fabrication of inner 3D structures of aero engines and gas turbines as well as the repair of local damages in oil drilling tools. The core element of the modularly designed ID cladding head presented here is a multi-jet coaxial Powder Nozzle. This Nozzle concept permits a precise Powder supply in any welding position, independently from gravity and welding direction. Thus, not only simple inner coatings are applicable, but also complex shaped metal structures can be generated in internal areas with restricted accessibility. All media supply, such as Powder, shielding gas, cooling water, is safely packaged inside the processing head. The optical elements for shaping and focusing the laser beam are interchangeable and permit the use of disc an d Nd:YAG laser up to 3 kW laser power. Currently, the minimum ID caliber is 4 inches, and the maximum immersion depth amounts to 40 inches. Current developme...

  • New developments in surface technology and prototyping
    First International Symposium on High-Power Laser Macroprocessing, 2003
    Co-Authors: T. Himmer, Eckhard Beyer
    Abstract:

    Novel lightweight applications in the automotive and aircraft industries require advanced materials and techniques for surface protection as well as direct and rapid manufacturing of the related components and tools. The manufacturing processes presented in this paper are based on multiple additive and subtractive technologies such as laser cutting, laser welding, direct laser metal deposition, laser/plasma hybrid spraying technique or CNC milling. The process chain is similar to layer-based Rapid Prototyping Techniques. In the first step, the 3D CAD geometry is sliced into layers by a specially developed software. These slices are cut by high speed laser cutting and then joined together. In this way laminated tools or parts are built. To improve surface quality and to increase wear resistance a CNC machining center is used. The system consists of a CNC milling machine, in which a 3 kW Nd:YAG laser, a coaxial Powder Nozzle and a digitizing system are integrated. Using a new laser/plasma hybrid spraying technique, coatings can be deposited onto parts for surface protection. The layers show a low porosity and high adhesion strength, the thickness is up to 0.3 mm, and the lower effort for preliminary surface preparation reduces time and costs of the whole process.

  • Recent developments in metal laminated tooling by multiple laser processing
    Rapid Prototyping Journal, 2003
    Co-Authors: T. Himmer, Anja Techel, Steffen Nowotny, Eckhard Beyer
    Abstract:

    Time reduction and quick geometrical changes of complex components and tools are currently the most important demands in product development. The manufacturing process presented in this paper is based on multiple additive and subtractive technologies such as laser cutting, laser welding, direct laser metal deposition and CNC milling. The process chain is similar to layer-based Rapid Prototyping Techniques. In the first step, the 3D CAD geometry is sliced into layers by a specially developed software. These slices are cut by high speed laser cutting and then joined together. In this way laminated tools or parts are built. To improve surface quality and to increase wear resistance a CNC machining center is used. The system consists of a CNC milling machine, in which a 3 kW Nd:YAG laser, a coaxial Powder Nozzle and a digitizing system are integrated.

Jyh Hwa Tzou - One of the best experts on this subject based on the ideXlab platform.

  • The Development of Direct Metallic Rapid Tooling System
    IEEE Transactions on Automation Science and Engineering, 2007
    Co-Authors: Jyh Hwa Tzou
    Abstract:

    In recent years, rapid tooling (RT) has become increasingly important because of the requirement of rapid manufacturing. RT can be used to produce temporary molds as well as permanent molds in mass production. RT provides more benefits from the design stage to mass production. The objective of this research is to develop the direct metallic RT system and identify process parameters of laser cladding. A 2.5-kW Nd-AG laser system, a metallic Powder feeder system, a lateral Powder Nozzle system, a PC-based motion controller, and a shielding gas-supply system are incorporated for the hardware architecture in the proposed RT system. The critical process parameters influencing the dimensional accuracy were analyzed with Taguchi's experimental design. From the analysis of variance computational results, the factors "Scanning speed" and "Tool path offset" are the influential factors affecting the layer thickness of RT parts. From the experimental results, the dimensional accuracy of the dual Nozzle RT system is better than the single-Nozzle RT system. Finally, the proposed RT system could fabricate the mold inserts. After finishing the mold inserts and assembling the plenary injection mold, the injection molding machine can generate acrylonitrile butadiene styrene plastic parts with excellent quality. Note to Practitioners-Rapid prototyping (RP) technologies have provided a new way of making models or producing visualization prototype in a fast fashion. However, there is an urgent demand from the industry for much faster ways to make physical prototypes, with the desired material using the appropriate production method. RP technologies have introduced a new generation of RT processes. Producing tooling directly from computer-aided-design (CAD) models is regarded as an important process of reducing the cost and time to market for new products. In this paper, a direct metallic rapid tooling (RT) system is developed to fabricate the metallic parts and molds directly from 3-D CAD models. The experimental investigations are implemented to study the proposed RT system. Using Taguchi's method, the critical performance process parameters have been analyzed. The analysis of variance method is used to decide the important process parameters. The developed RT system can produce the mold inserts directly. After assembling the plenary injection mold, the Acrylonitrile butadiene styrene ABS plastic parts have been generated from this RT mold to demonstrate the success of the process. In the future, it is possible to develop a grading alloy RT system, which can control the ratio of the alloy grading layers. Because the grading alloy rapid mold can use varied metallic Powders with varied ratio, the cooling time and the residual stress can be reduced. Furthermore, the RT system can also adopt the coaxial Nozzle which can be integrated with the optical system. The advantage of the coaxial Nozzle is the independence of the Powder supply direction in which the workpiece moves

  • ICRA - Automated Desktop Manufacturing: Direct Metallic Rapid Tooling System
    Proceedings of the 2005 IEEE International Conference on Robotics and Automation, 2005
    Co-Authors: Ren C. Luo, Jyh Hwa Tzou, Cheng Lung Chang, Zhong Hong Huang
    Abstract:

    In recent years, Rapid Tooling (RT) has become more important because of the requirement of rapid manufacturing. RT can be used to produce temporary mold, even permanent mold in mass production. RT makes more benefit from design stage to mass production. The objective of this research is to develop the Direct Metallic Rapid Tooling System and identify process parameters of laser cladding. A metallic Powder feeder system, a three-axis motion control system, a 500W Nd-YAG laser system, a shielding gas supply system, and a Powder Nozzle are incorporated for the hardware architecture in Direct Metallic Rapid Tooling System. Besides, the designed software that includes slicing algorithm with bucket sorting, contour generation and tool path generation algorithm are presented briefly. Effort was attempted to find out the better process parameters of laser cladding using single clad and cladding layer techniques. Based on the investigation, some metallic RT parts were fabricated and discussed.

  • Rapid tooling using laser powered direct metallic manufacturing process
    31st Annual Conference of IEEE Industrial Electronics Society 2005. IECON 2005., 2005
    Co-Authors: Cheng Lung Chang, Jyh Hwa Tzou
    Abstract:

    Rapid tooling (RT) has recently become more important due to the requirement of rapid manufacturing in industrial automation field. RT can be used to produce temporary mold even permanent mold in mass production and to speed up compressed time into market. It makes more benefit from design stage to mass production. This study aims to develop the rapid tooling using laser powered direct metallic manufacturing process and identify process parameters of laser cladding. A metallic Powder feeder system, a three-axis motion control system, a Nd:YAG laser system, a shielding gas supply system, and dual Powder Nozzle are integrated into the hardware architecture of laser powered direct metallic rapid tooling system. We attempt to find out the better process parameters of laser cladding by the Taguchi's method. This system has been successfully demonstrated and some metallic RT molds and plastic injection molded part are fabricated through this proposed method.

Zhong Hong Huang - One of the best experts on this subject based on the ideXlab platform.

  • ICRA - Automated Desktop Manufacturing: Direct Metallic Rapid Tooling System
    Proceedings of the 2005 IEEE International Conference on Robotics and Automation, 2005
    Co-Authors: Ren C. Luo, Jyh Hwa Tzou, Cheng Lung Chang, Zhong Hong Huang
    Abstract:

    In recent years, Rapid Tooling (RT) has become more important because of the requirement of rapid manufacturing. RT can be used to produce temporary mold, even permanent mold in mass production. RT makes more benefit from design stage to mass production. The objective of this research is to develop the Direct Metallic Rapid Tooling System and identify process parameters of laser cladding. A metallic Powder feeder system, a three-axis motion control system, a 500W Nd-YAG laser system, a shielding gas supply system, and a Powder Nozzle are incorporated for the hardware architecture in Direct Metallic Rapid Tooling System. Besides, the designed software that includes slicing algorithm with bucket sorting, contour generation and tool path generation algorithm are presented briefly. Effort was attempted to find out the better process parameters of laser cladding using single clad and cladding layer techniques. Based on the investigation, some metallic RT parts were fabricated and discussed.

Ren C. Luo - One of the best experts on this subject based on the ideXlab platform.

  • ICRA - Automated Desktop Manufacturing: Direct Metallic Rapid Tooling System
    Proceedings of the 2005 IEEE International Conference on Robotics and Automation, 2005
    Co-Authors: Ren C. Luo, Jyh Hwa Tzou, Cheng Lung Chang, Zhong Hong Huang
    Abstract:

    In recent years, Rapid Tooling (RT) has become more important because of the requirement of rapid manufacturing. RT can be used to produce temporary mold, even permanent mold in mass production. RT makes more benefit from design stage to mass production. The objective of this research is to develop the Direct Metallic Rapid Tooling System and identify process parameters of laser cladding. A metallic Powder feeder system, a three-axis motion control system, a 500W Nd-YAG laser system, a shielding gas supply system, and a Powder Nozzle are incorporated for the hardware architecture in Direct Metallic Rapid Tooling System. Besides, the designed software that includes slicing algorithm with bucket sorting, contour generation and tool path generation algorithm are presented briefly. Effort was attempted to find out the better process parameters of laser cladding using single clad and cladding layer techniques. Based on the investigation, some metallic RT parts were fabricated and discussed.

Michael Rethmeier - One of the best experts on this subject based on the ideXlab platform.

  • Build-up strategies for additive manufacturing of three dimensional Ti-6Al-4V-parts produced by laser metal deposition
    Journal of Laser Applications, 2018
    Co-Authors: Felix Spranger, Benjamin Graf, Michael Schuch, Kai Hilgenberg, Michael Rethmeier
    Abstract:

    Laser metal deposition (LMD) has been applied as a coating technology for many years. Today, the technologies capacity to produce 3D depositions leads to a new field of application as additive manufacturing method. In this paper, 3D laser metal deposition of titanium alloy Ti-6Al-4 V is studied with special regard to the demands of additive manufacturing. Therefore, only the coaxial LMD Powder Nozzle is used to create the shielding gas atmosphere, which ensures high geometric flexibility. Furthermore, specimen with high aspect ratio and hundreds of layers are manufactured, which represent typical features in additive manufacturing. The presented study contains the following steps: First, cylindrical specimens are manufactured with a standard shell-core build-up strategy and mechanical properties as well as fracture mechanisms are determined. Based on the results, experiments are conducted to improve the build-up strategy and new tensile test specimens are built with the improved strategy. The improved strategy incorporates variable track overlap ratios to achieve a constant growth in the shell and core area. As blanks, lean cylinders comprising more than 240 layers and a height of more than 120 mm are manufactured. The specimens are analyzed by X-ray inspection for material defects. Fractured surfaces are observed via scanning electron microscopy and the composition of the surfaces is determined using energy dispersive X-ray spectroscopy. The tensile test results prove mechanical properties close to ASTM F1108 specification for wrought material.Laser metal deposition (LMD) has been applied as a coating technology for many years. Today, the technologies capacity to produce 3D depositions leads to a new field of application as additive manufacturing method. In this paper, 3D laser metal deposition of titanium alloy Ti-6Al-4 V is studied with special regard to the demands of additive manufacturing. Therefore, only the coaxial LMD Powder Nozzle is used to create the shielding gas atmosphere, which ensures high geometric flexibility. Furthermore, specimen with high aspect ratio and hundreds of layers are manufactured, which represent typical features in additive manufacturing. The presented study contains the following steps: First, cylindrical specimens are manufactured with a standard shell-core build-up strategy and mechanical properties as well as fracture mechanisms are determined. Based on the results, experiments are conducted to improve the build-up strategy and new tensile test specimens are built with the improved strategy. The improved str...

  • Build-up strategies for additive manufacturing of three dimensional Ti-6Al-4V-parts produced by laser metal deposition
    International Congress on Applications of Lasers & Electro-Optics, 2017
    Co-Authors: Felix Spranger, Benjamin Graf, Michael Schuch, Kai Hilgenberg, Michael Rethmeier
    Abstract:

    Laser metal deposition (LMD) has been applied as coating technology for many years. Today, the technologies capacity to produce 3D depositions leads to a new field of application as additive manufacturing method. In this paper, 3D laser metal deposition of titanium alloy Ti-6Al-4V is studied with special regard to the demands of additive manufacturing. Therefore, only the Powder Nozzle is used to create the shielding gas atmosphere, which ensures high geometric flexibility. Furthermore, specimen with high aspect ratio and hundreds of layers are manufactured, which represent typical features in additive manufacturing.The presented study contains the following steps: First, cylindrical specimens are manufactured with a standard core-shell build-up strategy and mechanical properties as well as fracture mechanisms are determined. Based on the results, experiments are conducted to improve the build-up strategy and new tensile test specimens are built with the improved strategy. The improved strategy incorporates variable track overlap ratios to achieve a constant growth in shell and core area. As blanks, lean cylinders comprising more than 240 layers and a height of 120 mm are manufactured. The specimens are analyzed by X-ray inspection for material defects. Fractured surfaces are observed via scanning electron microscopy (SEM) and the composition of the surfaces is determined using energy dispersive x-ray spectroscopy (EDX). The tensile test results prove mechanical properties close to ASTM F1108 specification for wrought material.Laser metal deposition (LMD) has been applied as coating technology for many years. Today, the technologies capacity to produce 3D depositions leads to a new field of application as additive manufacturing method. In this paper, 3D laser metal deposition of titanium alloy Ti-6Al-4V is studied with special regard to the demands of additive manufacturing. Therefore, only the Powder Nozzle is used to create the shielding gas atmosphere, which ensures high geometric flexibility. Furthermore, specimen with high aspect ratio and hundreds of layers are manufactured, which represent typical features in additive manufacturing.The presented study contains the following steps: First, cylindrical specimens are manufactured with a standard core-shell build-up strategy and mechanical properties as well as fracture mechanisms are determined. Based on the results, experiments are conducted to improve the build-up strategy and new tensile test specimens are built with the improved strategy. The improved strategy incorporat...

  • Combined Laser Additive Manufacturing for Complex Turbine Blades
    Global Nuclear Safety, 2016
    Co-Authors: Benjamin Graf, Andrey Gumenyuk, Sergej Gook, Michael Rethmeier
    Abstract:

    Laser beam processes are increasingly used in the field of additive manufacturing. Prominent methods are either Powderbed-based like Laser Metal Fusion (LMF), or utilizing a Powder Nozzle like Laser Metal Deposition (LMD). While LMF allows the manufacturing of complex structures, build rate, part volumes and material flexibility are limited. In contrast, LMD is able to operate with high deposition rates on existing parts, and materials can be changed easily during the process. However LMD shape complexity is limited. Utilizing their respective strengths, a combination of these two additive technologies has the potential to produce complex parts with high deposition rates and increased material flexibility. In this paper, combined manufacturing with additive technologies LMF and LMD is described. Its benefit for industry with emphasis on turbomachinery is shown. As reality test for the innovation, an industrial turbine blade is manufactured.

  • Combined laser additive manufacturing with Powderbed and Powder Nozzle for turbine parts
    2016
    Co-Authors: Benjamin Graf, Michael Schuch, T. Petrat, Andrey Gumenyuk, Michael Rethmeier
    Abstract:

    Metal additive manufacturing is often based on laser beam processes like Laser Metal Fusion (LMF) or Laser Metal Deposition (LMD). The LMF process is in particular suitable for very complex geometries. However build rate, part volume and material flexibility are limited in LMF. In contrast, LMD achieves higher deposition rates, less restricted part sizes and the possibility to change the material composition during the build-up process. On the other hand, due to the lower spatial precision of the material deposition process, the complexity of geometries is limited. Therefore, combined manufacturing with both LMF and LMD has the potential to utilize the respective advantages of both technologies. In this paper, combined additive manufacturing with LMF and LMD is described for Ti-6Al-4V and Inconel 718. First, lattice structures with different wall thickness and void sizes are built with LMF. The influence of LMD material deposition on these LMF-structures is examined regarding metallurgical impact and distortion. Cross-sections, x-ray computer tomography and 3D-scanning results are shown. For the titanium alloy specimen, oxygen and Nitrogen content in the deposited material are analysed to evaluate the LMD shielding gas atmosphere. The results are used to develop guidelines for a LMD build-up strategy on LMF substrates. With these findings, a gas turbine burner is manufactured as reality test for the combined approach.