A5026243260- Additive Manufacturing Materials and Processes
- High Entropy Alloys Studies
- Additive Manufacturing and 3D Printing Technologies
- Welding Techniques and Residual Stresses
- Laser-induced spectroscopy and plasma
- Metal and Thin Film Mechanics
- High-Temperature Coating Behaviors
- Tribology and Lubrication Engineering
- Laser Material Processing Techniques
- Advanced Measurement and Metrology Techniques
- Particle Dynamics in Fluid Flows
- Manufacturing Process and Optimization
- Titanium Alloys Microstructure and Properties
- Advanced Surface Polishing Techniques
- Advanced machining processes and optimization
- Aluminum Alloys Composites Properties
- Advanced Materials Characterization Techniques
- Advanced Photocatalysis Techniques
- Advanced Thermoelectric Materials and Devices
- Fluid Dynamics and Heat Transfer
- Advanced Machining and Optimization Techniques
- Surface Roughness and Optical Measurements
- Metallurgy and Material Science
- Machine Learning in Materials Science
- Metallurgical and Alloy Processes
Fraunhofer Institute for Laser Technology
2015-2024
RWTH Aachen University
2011-2020
The development of new coating technologies for the wear and corrosion protection large, high-quality components in manufacturing industry is becoming more significant, not only from an economic but also ecological perspective. In various branches such as aerospace, oil gas, automotive, papermaking, others, hard chrome plating (HCP) a widespread, standard process. However, implementations EU directives 1999/13/EC (VOC), 2011/65/EU (RoHS), 2012/19/EU (WEEE) well regulation EC 1907/2006...
Abstract Special coatings protect components against corrosion and wear. However, standard processes such as hard chrome plating, thermal spraying, laser material deposition or other welding techniques have drawbacks. For example, of September 2017, chromium(VI) will require authorization. Researchers from the Fraunhofer Institute for Laser Technology ILT in Aachen well RWTH University now developed an extreme high‐speed process, known by its German acronym EHLA, to eliminate these drawbacks...
Abstract The energy transition is one of the main challenges our society and therefore a major driver for scientific community. To ensure smart to sustainable future scenario different technologies such as harvesting using solar cells or windmills chemical storage in batteries, super-capacitors hydrogen have be developed ultimately deployed. New fabrication approaches based on additive manufacturing digitalization industrial processes increase potential achieve highly efficient required...
Laser metal deposition (LMD) is one of the most important laser additive manufacturing processes. It can be used to produce functional coatings, repair damaged parts and manufacture components. Ti6Al4V commonly titanium alloys, since it features a good balance mechanical properties strength ductility. The LMD attracting more attention from both science engineering. interest in processing with industry, especially aerospace medical branches, has been increasing last few years. In this paper,...
A variant of conventional laser material deposition (LMD), extreme high-speed (German acronym: EHLA) is characterized by elevated process speeds up to 200 m/min, increased cooling rates, and a significantly reduced heat affected zone. This study focuses on the feasibility using EHLA apply onto Fe-based substrate materials with AISI 4340 as filler material. We studied how three different build-up strategies—consisting one, three, five consecutive deposited layers hence, thermal evolutions...
Porosity is a limiting factor in the processing of aluminum-alloys with Directed Energy Deposition (DED) and other Additive Manufacturing technologies, such as Laser Powder Bed Fusion. Especially mechanical properties additively manufactured samples are strongly dependent from porosity, thus, understanding parameters influencing porosity crucial. In this work, detailed study factors, which usually not considered but can affect AlMgScZr-alloy DED samples, presented. To end, influence powder...
Extreme high-speed laser material deposition (EHLA) is a variant of (LMD) with modified powder gas jet focus. EHLA allows at high process speeds in the range several hundred meters per minute and layers as thin 25 μm. Feed rates can be 50 g/min or above. The processing combinations poor weldability different melting points possible, simultaneously smaller heat-affected zone dilution compared to conventional LMD. Until now, has mainly been used for applying wear-resistant corrosion-resistant...
For several years, the interest in additive manufacturing is continuously expanding, owing to paradigm shift that new production processes, such as laser material deposition (LMD), provide over conventional technologies. With LMD, three-dimensional, complex components out of a wide range materials can be manufactured consecutively layer-by-layer. However, aiming for large with currently achieved deposition-rates approximately 0.5 kg/h remain major concern regards processing time and economic...
Extreme high-speed laser material deposition, known by its German acronym EHLA, is a new variant of deposition (LMD) with powdered additives. This variant’s process control unlike that LMD, where the powder melts as it contacts melt pool. In EHLA process, beam above surface substrate to deliver liquid At given intensity distribution in beam, heating particles path depends largely on three-dimensional particle density (PDD) and relative position within caustic. As key element comprehensive...
Extreme high-speed directed energy deposition (EHLA) is a variant of (DED-LB) developed at Fraunhofer ILT in cooperation with RWTH Aachen University. Because powder gas jet setup that aimed melting particles the laser beam before they enter pool, high process speeds up to several hundred meters per minute and layer thickness as thin 25 μm can be achieved. EHLA generally applied for rotationally symmetric coating applications. In previous experiments on prototype machine ponticon GmbH, was...
Laser metal deposition (LMD) process has been widely used in many industrial applications such as automotive, defense, aerospace, and so on. Modeling to address physical phenomena like laser-powder interaction, heat transfer, fusion, solidification, track formation. LMD induces a complex thermal stress field that results residual distributions. Depending on its magnitude nature (i.e., whether tensile or compressive), the stresses can cause unpredicted in-service failures. Therefore,...
Additive manufacturing technologies such as laser material deposition (LMD) enable manufacturers to economically produce complex and individualized products. However, improved productivity more economic use of LMD are necessary benefit from these advantages in a wider range applications. Through the industrial robots applications, large workspaces geometric flexibility can be achieved at low cost. Possible effects reduced path accuracies compared conventional machines for not currently...
The context of future laser applications in modern manufacturing can be summarized by Digital Photonic Production (DPP). "From Bits to Photons Atoms" describes the vision DPP: Designing a component or product computer and creating it directly additive subtractive photon based processes production-systems.
Extreme high-speed directed energy deposition (EHLA) is a modified variant of the laser based (DED-LB) and being applied as an efficient coating process for rotational symmetric components. Characteristics EHLA processes are feed rates up to 200 m/min, which result in smaller weld bead thinner layer thicknesses compared conventional DED-LB. When transferred additive manufacturing, this characteristic utilizes potential depositing thin-walled filigree structures at rates, comparable typical...
This work focuses on the development of 3D Extreme High-Speed DED process (EHLA3D), a variant laser-based Directed Energy Deposition (DED-LB), for processing material HSS M2. Characteristics EHLA3D are feed rates >20 m/min, high cooling rates, and layer thicknesses in range 100 µm. covers three subsequent stages: (1) parameter study single-track deposition, (2) coating parameters, (3) parameters AM. In scope stage 2, with powder mass flow ṁ = 1.9 kg/h was achieved. A variation deposition...
Extreme high-speed directed energy deposition (German acronym—EHLA) is a modified variant of the laser based (DED-LB) and being applied as an efficient coating process for rotational symmetric components. Recent advancements regarding available machine kinematics enable utilization originally 2D 3D so that EHLA technology can be used additive manufacturing, repair, free-form applications. Compared to conventional DED-LB, results in lower surface roughness; however, subtractive postprocessing...
Laser material deposition (LMD) is a laser-based additive manufacturing process that widely used for fabrication, diversification, and repair of parts in various industries. LMD processes can be distinguished by the form filler material. In terms availability, storage, safe handling, price, wire often has advantages over powdered materials. this work, influence tool path planning on accuracy stability with coaxial feed studied. The laser beam are arranged coaxially to each other, being fed...
Aluminum-magnesium-scandium-zirconium (AlMgScZr) alloys need to be rapidly cooled from the liquid state obtain a high degree of solute supersaturation that helps exploit precipitation hardening potential material. While AlMgScZr have been successfully used in laser powder bed fusion (LPBF) processes, there has little research field directed energy deposition (DED) The limited previous studies shown performance parts fabricated with DED only reached about 60% LPBF. In view breaking through...
Corrosion causes costs of about 3-4% each country's gross domestic product, and due to the climate change, corrosion rates on infrastructure are likely increase furtherly in future1,2. For protection, hard chrome plating (HCP) is commercially used since early 20th3. Yet biggest drawback concerns environmental toxic carcinogenic hexavalent chromium Cr6+ used. As an alternative, thermal spray (TS) increasingly last 20 years. Nevertheless, coatings technologically constrained regard high...
Abstract Originally created as an alternative to coating processes such hard chrome plating and thermal spraying, the Fraunhofer Institute for Laser Technology ILT is working with industry partners transform this extremely high‐speed form of laser material deposition into a fast affordable additive manufacturing process. The goal push boundaries 3D printing achieve high rates at resolution new technology special nozzle including kind measuring system.