New Developments in 3D Laser Additive Manufacturing
Authors:
James Sears, South Dakota School of Mines & Technology; Rapid City SD USA
Vojislav Kalanovic, Control Systems Technology; Rapid City SD USA
Jovan Mirilovic, -; -
Presented at ICALEO 2009

Laser Additive Manufacturing (LAM) titanium powder consolidation has been practiced for a number of years. The LAM technology holds great promise for repair, direct fabrication and modification of Titanium Alloy components, This technology can also provide for surface modification through alloying and physical texturing. The LAM technology has been applied to the development of a number of aerospace applications through its ...

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Direct Fabrication of a Ti-47Al-2Cr-2Nb Alloy by Selective Laser Melting and Direct Metal Deposition Processes
Authors:
Christophe Colin, Centre Des Materiaux, Mines Paris, Paristech; Evry France
Ludovic Thivillon, Enise; Saint-Etienne France
Marc Thomas, Onera; Chatillon France
PASCAL AUBRY, CEA; Gif-sur-Yvette France
Patrice Peyre, Arts Et M�Tiers Paristech; Paris France
Philippe Bertrand, Enise; Saint-Etienne France
Thierry Malot, Arts Et M�Tiers Paristech; Paris France
Thomas Vilaro, Centre Des Materiaux, Mines Paristech; Evry France
Vera Kottman-Rexerodt, Onera; Chatillon France
Vincent Ji,...

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Laser Deposition of TI6Al4V-316L Composition Gradient Structure: Challenge on Intermetallics
Authors:
Changsheng Dong, Tsinghua University, Dept of Mechanical Engineering; Beijing Peoples Republic of China
Minlin Zhong, Tsinghua University; Beijing Peoples Republic of China
Wenjin Liu, -; -
Minxing Ma, -; -
Hongjun Zhang, -; -
Presented at ICALEO 2009

Functional gradient materials (FGM), with their composition gradually varied in different positions, have attracted much attention for research and development during the years. Normally there are two types of functional gradient materials: one without the formation of intermetallics which is ...

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A Method and Model for Deposition of TI-6Al-4V with Controlled Porosity
Authors:
Muhammad Naveed Ahsan, Manufacturing and Laser Processing Group,The University of Manchester; Manchester Great Britain
Andrew J Pinkerton, Manufacturing and Laser Processing Group,The University of Manchester; Manchester Great Britain
Presented at ICALEO 2009

The use of porous engineered materials is gaining popularity in biomedical implant manufacture due to its capability to promote increased osseointegration and cell proliferation. A method to produce such parts is laser direct metal deposition (LDMD) - a rapid manufacturing technique that has much flexibility. In this work, a 1.5 kW high power diod...

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Phase Evolution in Laser Solid Formed Compositionally Graded Ti60-Ti2AlNb Alloys
Authors:
Xin Lin, Northwestern Polytechnical University; Xi'an Peoples Republic of China
Mocong Yang, State Key Laboratory of Solidification Processing, Northwestern Polytechnical University; Xi\'An Peoples Republic of China
Xiaojing Xu, State Key Laboratory of Solidification Processing, Northwestern Polytechnical University; Xi\'An Peoples Republic of China
Haiou Yang, -; -
Jing Chen, State Key Laboratory of Solidification Processing, Northwestern Polytechnical University; Xi\'An Peoples Republic of China
Weidong Huang, State Key Laboratory of Solidification Process...

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The Effects of Surface Topography and Lack of Fusion on the Fatigue Strength of Laser Hybrid Welds
Authors:
Md. Minhaj Alam, Lulea University of Technology; Lule� Sweden
Zuheir Barsoum, Royal Institute of Technology (KTH); Stockholm Sweden
Per Jonsen, Lulea University of Technology; Lulea Sweden
Hans Ake Haggblad, Lulea University of Technology; Lulea Sweden
Alexander Kaplan, Lulea University of Technology; Lulea Sweden
Presented at ICALEO 2009

The geometrical aspects of laser hybrid welding before, during and after the process differ from autonomous laser welding and from arc welding. When studying the fatigue behaviour of laser hybrid weld...

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Diffusible Hydrogen Characteristics of Hybrid Laser Arc Welding (HLAW)
Authors:
Paul A. Blomquist, Applied Thermal Sciences, Inc.; Sanford ME USA
Stanley E. Ferree, ESAB Welding and Cutting Products; - USA
Brian M. Marx, Concurrent Technologies Corp; - USA
Presented at ICALEO 2009

With the increased interest in Hybrid Laser Arc Welding (HLAW) in the U.S., the process is being certified for use on increasingly higher strength steels. The addition of the laser to the traditional Gas Metal Arc Welding (GMAW) process results in a higher total melt volume than that of the GMAW process alone. Studies of hydrogen content of HLAW welds were carried out in which comparisons w...

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Comparative Analysis of GMA, Laser and Laser-GMA Hybrid Welding
Authors:
Jukka Siltanen, Rautaruukki Oyj; Hämeenlinna Finland
Markus Suomi, Helsinki University of Technology; Helsinki Finland
Presented at ICALEO 2009

Laser welding and laser-MAG hybrid welding are used more often in heavy industry. It is very typical that a product earlier welded by arc welding needs changes to its design when laser or laser-MAG hybrid welding processes are considered. This presentation is based on a Master’s thesis, the aim of which was to give guidelines for structural designers. The material used in the welding tests was S355K2 (according to EN 10025-2:2004). Joint geometries were butt and T-j...

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Criterion for Online Evaluation of Penetration Status in Laser-MIG Hybrid Welding and Its Application
Authors:
Yongqiang Zhang, Shougang Research Institute of Technology; Beijing Peoples Republic of China
Wuzhu Chen, Department of Mechanical Engineering,Tsinghua University; Beijing Peoples Republic of China
Yuanqing Shuang, Department of Mechanical Engineering,Tsinghua University; Beijing Peoples Republic of China
Jun Zhang, Shougang Research Institute of Technology; Beijing Peoples Republic of China
Presented at ICALEO 2009

The root penetration status in hybrid butt welding is the most important criterion for evaluating the weld joint quality. The weld ro...

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Monitoring of Hybrid Laser-Arc Welding of Galvanized Steels in a Gap-Free Lap Joint Configuration
Authors:
Shanglu Yang, Southern Methodist University; Dallas TX USA
Rouzbeh Sarrafi, -; -
Radovan Kovacevic, -; -
Presented at ICALEO 2009

Hybrid laser-arc Welding of galvanized steels in a gap-free lap joint configuration is a complicated welding process, which is involved in many welding parameters such as laser power, welding speed as well as the distance between laser beam and GTAW torch. Furthermore, the dynamic behaviors of the molten pool, which reflect the stability of the welding process, is significantly affected by the dynamic behaviors of highly-pressurized z...

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High Brightness Hybrid Welding of Steel
Authors:
Brian Victor, EWI; Columbus OH USA
Brad Nagy, EWI; Columbus OH USA
Stan Ream, EWI; Columbus OH USA
Dave Farson, Ohio State University; Columbus OH USA
Presented at ICALEO 2009

With the increasing power and performance of high-brightness solid-state lasers, laser-GMAW hybrid welding is becoming more practical for thick-section welding applications. This study evaluated hybrid welding of steel butt joints with a 10kW fiber laser. Welding trials were conducted to evaluate the effect that beam-to-wire distance and process orientation (arc-leading vs. laser-leading) had on the hybrid process. Both full and par...

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On the Meaning of Zinc Coatings in Hybrid Welding of Aluminium to Steel
Authors:
Frank Vollertsen, BIAS GmbH; Bremen Germany
Claus Thomy, BIAS GmbH; Bremen Germany
Presented at ICALEO 2009

Laser MIG hybrid welding was recently suggested as a feasible process for joining of aluminium to steel for both structural and tailored blank applications. In this process, the aluminium is molten to create a brazed bond to the zinc-coated steel sheet, which remains solid. To further investigate the effect of process parameters, laser power, MIG arc power, wire feed rate, welding speed and arc position relative to the abutting edges were varied for the case of butt joints of aluminium alloy AA 6...

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Fiber Laser Assisted Machining of Silicon Nitride
Authors:
Federico Sciammarella, Northern Illinois University; DeKalb IL USA
Michael Matusky, Northern Illinois University; Dekalb IL USA
Presented at ICALEO 2009

Laser Assisted Machining (LAM) of ceramics is an important area of research concerning the improvement upon conventional diamond grinding machining processes. The problems associated with the machinability of these advanced ceramic materials, specifically silicon nitride (Si3N4), have already lead to previous research work done with LAM. Utilizing the advent of high power fiber diode lasers, current research can now be completed outside the realm of traditional lasers such...

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Assessment of Part Quality in Laser Assisted Milling of Silicon Nitride Ceramic
Authors:
Budong Yang, Kansas State University; Manhattan KS USA
Jiangang Sun, Argonne National Laboratory; Argonne IL USA
Elizabeth Frink, Kansas State University; Manhattan KS USA
Shuting Lei, Kansas State University; Manhattan KS USA
Kevin Lease, Kansas State University; Manhattan KS USA
Presented at ICALEO 2009

Due to the high brittleness of ceramic materials, the performance of ceramic components is very sensitive to machining damage. As laser assisted machining (LAM) poises to become a potentially cost-effective machining process for structural ceramics such a...

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Laser-based Machining of Fine Features Scales for High Precision Optical Position Encoders
Authors:
Stephanie Giet, Heriot Watt University; Edinburgh Scotland
Charalampos Michakis, Heriot Watt University; Edinburgh Scotland
Jonathan Parry, Heriot Watt University; Edinburgh Scotland
Matthew Kidd, Renishaw Plc; Edinburgh Scotland
A. Ellin, -; -
Jonathan Shephard, Heriot Watt University; Edinburgh Scotland
Nick Weston, Renishaw Plc; Edinburgh Scotland
Duncan Hand, Heriot Watt University; Edinburgh Scotland
Presented at ICALEO 2009

High precision optical motion encoders provide reliable high-accuracy positio...

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High Pulse Energy (HPE) Picosecond (ps) Laser
Authors:
Joyce Kilmer, Photonics Industries International, Inc.; Bohemia NY USA
Santosh Pisharody, Photonics Industries International, Inc.; Bohemia NY USA
Yusong Yin, Photonics Industries International, Inc.; Bohemia NY USA
Presented at ICALEO 2009

High Pulse Energy (HPE) Picosecond (ps) lasers are effective tools for processing a wide range of materials ranging from brittle samples that exhibit chipping/cracking to metals or composite materials such as the novel thin film solar cell material, Copper indium gallium selenide (CIGS), which suffer thermal deformation from long pulse laser processing. Mechanically machining me...

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Overcoming Limits in Processing of Advanced Material Geometries
Authors:
Henk Kettelarij, Philips Applied Technologies; Eindhoven Netherlands
Presented at ICALEO 2009

Standard laser processing technologies available on industrial scale often cannot fulfill specific requirements for processing advanced material geometries. A number of dedicated hardware and software solutions to overcome these limitations have been developed within Philips Applied Technologies. In this presentation some of these developments will be discussed. Maximizing processing speed for accurate micromachining of funnel shaped holes requires in depth knowledge of scanner dynamics. By carefully designing scanner tracks with...

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New Low-cost CO2 Beam Profiler Eliminates Need for Acrylic Mode Burns
Authors:
Lawrence Green, Ophir-Spiricon, Inc; Logan UT USA
Presented at ICALEO 2009

Acrylic Mode Burns have historically been universally used because they are the lowest cost alternative to the budget-minded end user. This method, however has been cited for producing dangerous, cancer-causing airborne materials, and is not a real time technology. On the other hand, Real-time beam profiling has been historically too expensive for the average user to acquire. We discuss a new technology that enables the design of a new low-cost real time CO2 high power beam profiler that is within reach of almost all end-users. This design do...

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Novel Beam Analysis Applications and Hardware
Authors:
Thomas Kugler, Laser Mechanisms, Inc; Farmington Hills MI USA
Presented at ICALEO 2009

Off-the-shelf beam analysis systems work very well in investigating and measuring collimated laser beam spatial profiles, focus spot spatial profiles, and the waist caustic. These standard systems have some shortcomings, however, related to viewing very small focus spot sizes at any wavelength, but especially at 10.6um. Another problem that these beam analysis systems can solve is alignment of optics and other components that can be damaged by high power beams if improperly set-up. This presentation will investigate the use of novel but simple imaging ...

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Development of a Real Time Monitoring and Adaptive Control System for Laser Flame Cutting
Authors:
J.P. Kruth, -; -
Joost Duflou, K.U.Leuven; Heverlee - Leuven Belgium
Ehsan Fallahi, K.U. Leuven; Heverlee Belgium
J. De Keuster, -; -
Presented at ICALEO 2009

A real-time, adaptive control and optimization system for laser flame cutting of thick plates of mild steel has been developed. The proposed system consists of two subsystems: a process monitoring system and a control and optimization system. The first subsystem aims at the on-line observation of the process status and corresponding cut quality. Since the different cut quality characteristics cannot ...

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Possibilities for Online Process Monitoring at Laser Brazing Based on Two Dimensional Detector Systems
Authors:
Alexander Grimm, blz Bayerisches Laserzentrum GmbH; Erlangen Germany
Michael Schmidt, blz Bayerisches Laserzentrum GmbH; Erlangen Germany
Presented at ICALEO 2009

Laser brazed seams are nowadays well established in automotive industry for joints which must fulfill high quality standards. Joints located in direct visible areas of the car body, like the connection between roof and side-panel or the trunk-lit, must be manufactured without any failures like pores or spilling. To achieve this goal, system technology is subject to high accuracy requests on the one hand; on the ...

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Direct Metal Deposition Melt Pool Temperature Distribution Control Through Novel Holographic Beam Shaping, Allowing Improved Mechanical and Corrosion Properties
Authors:
Matthew Gibson, Loughborough University; Loughborough Great Britain
John Tyrer, Loughborough University; Loughborough Great Britain
Rebecca Higginson, Loughbrough University; Loughborugh Great Britain
Presented at ICALEO 2009

The use of a laser beam to fuse a metal addition to the surface of a component for repair or direct manufacture has been adopted my many industries. However there are still issues to be overcome. Due to the high temperatures involved in the process and the complex materials utilis...

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On the Temperature Distributions and Thermal Stresses Induced in Laser Solid Freeform Fabrication of Multi-material Structures
Authors:
Masoud Alimardani, University of Waterloo; Waterloo ON Canada
Mehrdad Iravani Tabrizipour, University of Waterloo; Waterloo ON Canada
Ehsan Toyserkani, University of Waterloo; Waterloo ON Canada
Jan P. Huissoon, University of Waterloo; Waterloo ON Canada
Presented at ICALEO 2009

Multi-material structures have shown a wide range of applications in various advanced technologies in which diverse material properties are required in order to enhance the structural properties and functionalities. Laser solid freeform fabrication...

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Applied Spectroscopy In Situ during Direct Laser Deposition Process
Authors:
Konrad Bartkowiak, Fraunhofer IWS; Dresden Germany
Paul Denney, Presenter not author - CCAT; - USA
Presented at ICALEO 2009

The Direct Laser Deposition (DLD) method is becoming more popular and has recently been successfully applied in commercial workshops. It is mainly used for reconditioning of worn and damages parts and eliminating them from scrap. However, DLD technique shows great potential for direct manufacture, where high accuracy, low distortion and small HAZ effects are required. Especially the high accuracy makes a challenge for DLD process control, which is permanently developing and updated fr...

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The Exploration on Laser Vertical Sintering with Magnetic Field
Authors:
Xiaogang Li, National Center of Laser Technology, Beijing University of Technology; Beijing Peoples Republic of China
Jimin Chen, National Center of Laser Technology, Beijing University of Technology; Beijing Peoples Republic of China
Furong Liu, National Center of Laser Technology, Beijing University of Technology; Beijing Peoples Republic of China
Penfei Lv, National Center of Laser Technology, Beijing University of Technology; Beijing Peoples Republic of China
Presented at ICALEO 2009

Selective Laser Sintering (SLS) is a fast developing technology of Rapid Manufacturing (RM). In so...

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