Laser power density distribution metrology to support emerging trends in metal additive manufacturing

Published

September 11, 2024

Author(s)

David Deisenroth, Sergey Mekhontsev, Jordan Weaver, Samantha Webster

Abstract

The laser power density distribution (PDD) applied to a material is a predominant process parameter that directly affects the properties of parts that are built with metal additive manufacturing (AM). Despite its prevalent effect on melting (especially melting depth and cooling rate), accurate characterization of PDDs in metal AM has been largely inadequate because of the challenging nature of such measurements. The metrological challenges include 1) withstanding power densities on the order of 10 MW/cm2, 2) accurately positioning optical devices (ideally within ±50 µm) relative to a reference plane, 3) intercepting and accurately profiling high-power beams at incidence angles up to 20° off-normal, 4) accurately measuring beams that are scanned significantly faster than 1 m/s, and 5) measuring highly-dynamic, non-Gaussian beam profiles (beam shaping). This paper describes measurement approaches, challenges, and future research directions for metal AM beam metrology. Preliminary results of laser directed energy deposition experiments illustrate the importance of accurately quantifying PDDs.

Proceedings Title

13th CIRP Conference on Photonic Technologies [LANE 2024]

Volume

124

Conference Dates

September 15-19, 2024

Conference Location

Fürth, DE

Pub Type

Conferences

Download Paper

https://doi.org/10.1016/j.procir.2024.08.215

Local Download

Keywords

laser-based additive manufacturing, power density distribution metrology, beam shaping

Citation

Deisenroth, D. , Mekhontsev, S. , Weaver, J. and Webster, S. (2024), Laser power density distribution metrology to support emerging trends in metal additive manufacturing, 13th CIRP Conference on Photonic Technologies [LANE 2024], Fürth, DE, [online], https://doi.org/10.1016/j.procir.2024.08.215, https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=958177 (Accessed September 26, 2024)