OCT sensor for layer height control in DED using SINUMERIK® controller

Kogel‐Hollacher, Markus; Strebel, Matthias; Staudenmaier, Christian; Schneider, H.-I.; Regulin, Daniel

doi:10.1117/12.2540167

Cited by 11 publications

(7 citation statements)

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“…This sensor technology based on low-coherence interferometry (LCI) is already established in several laser material processing applications [44,45]. By splitting a coherent light beam, the relative distance between two reflecting surfaces can be determined based on the interference pattern of the reflected light beams [46]. The use of OCT for the height measurement in wire-based LMD offers several major advantages.…”

Section: A Novel Concept For Multivariable Process Controlmentioning

confidence: 99%

“…The use of OCT for the height measurement in wire-based LMD offers several major advantages. On the one hand, interferometric measurements are not influenced by process-induced electromagnetic emissions [46]. On the other hand, by integrating the measurement principle into the laser processing head, a spatially lean solution is achieved that does not limit accessibility.…”

Section: A Novel Concept For Multivariable Process Controlmentioning

confidence: 99%

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Laser Metal Deposition with Coaxial Wire Feeding for the Automated and Reliable Build-Up of Solid Metal Parts

Bernauer

Merk

Zapata

et al. 2022

KEM

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Due to their outstanding characteristics, additive manufacturing processes are attracting increasing industrial interest. Among these processes, laser metal deposition (LMD) is an innovative technology for the production of metal components. In order to create three-dimensional parts, wire or powder is deposited layer-wise onto a substrate. When wire is used as feedstock, major drawbacks of the powder-based process, such as the low material usage, contamination of the process cell with metal powder, and health or safety issues, can be overcome or even avoided. In addition, recent developments in laser optics allow for a coaxial wire feeding in the center of an annular laser beam. This eliminates the strong directional dependence of the process when feeding the wire laterally. However, wire-based LMD is highly sensitive to process disturbances, which impedes its broader industrial application. Since it is necessary to completely melt the fed wire to achieve a stable process, self-regulating effects such as overspray in powder-based LMD are not present. In contrast to the widely investigated thin walls, the build-up of multi-track solid structures poses a particular challenge. Therefore, process strategies for producing such solid structures are presented in this paper. The experiments were carried out using a laser processing head that enables coaxial wire feeding (CoaxPrinter, Precitec). By systematically varying the lateral overlap between adjacent weld beads, it was shown that an optimum exists at which minimum surface waviness is achieved. Based on this, defect-free multi-layer solid components could be generated in a reproducible manner. During the process, the melt pool temperature was evaluated using a pyrometer. Furthermore, a microscopic examination of the resulting parts was conducted. The results obtained show the need for process monitoring and control, for which a novel and holistic approach has been developed.

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Section: A Novel Concept For Multivariable Process Controlmentioning

confidence: 99%

Section: A Novel Concept For Multivariable Process Controlmentioning

confidence: 99%

Laser Metal Deposition with Coaxial Wire Feeding for the Automated and Reliable Build-Up of Solid Metal Parts

Bernauer

Merk

Zapata

et al. 2022

KEM

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“…The challenge today is when it comes to high production rates and high demand of quality required by a zero-defect process. Industrial production speeds can reach up to 5-10 batteries/sec and the assembly of a single battery pack can contain up to 20000 welds [5] . It is estimated that each Gigafactory produces 6% circa of defected cells and battery modules [6] .…”

Section: Introductionmentioning

confidence: 99%

Laser welding in e-mobility: process characterization and monitoring

Angeloni

2023

Materials Research Proceedings

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Abstract. Nowadays car manufacturers have to face the challenge of electric mobility transition and it is therefore becoming an industrial priority to accomplish a large-scale battery manufacturing based on high production rates and zero-defect processes that must be obtained over a very high variety of products. The above challenges are currently examined, at the Department of Industrial Engineering of the University of Bologna, by studying and optimizing laser processes (manly cutting and welding) in case of battery fabrication and assembly. Materials investigated are manly pure copper and aluminum, processed by means of different sources, wavelengths and scanning heads. In order to reach the quality targets requested by the market, an in-process monitoring system is implemented as well as physical and data driven simulation models are under development. Finally, comparisons between the monitoring output, the keyhole simulation results, and experimental data will be carried out.

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“…An intra-layer toolpath generation control procedure to increase the quality of the deposition process was also implemented, where an static camera system was used to observe the process [7]. For the LMWD process in specific, some sources demonstrated a track height control for laser metal deposition with powder [8].…”

Section: Introductionmentioning

confidence: 99%

Influence of a closed-loop controlled laser metal wire deposition process of S Al 5356 on the quality of manufactured parts before and after subsequent machining

Becker

Boley

Eisseler

et al. 2021

Prod. Eng. Res. Devel.

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This paper describes the interdependence of additive and subtractive manufacturing processes using the production of test components made from S Al 5356. To achieve the best possible part accuracy and a preferably small wall thickness already within the additive process, a closed loop process control was developed and applied. Subsequent machining processes were nonetheless required to give the components their final shape, but the amount of material in need of removal was minimised. The effort of minimising material removal strongly depended on the initial state of the component (wall thickness, wall thickness constancy, microstructure of the material and others) which was determined by the additive process. For this reason, knowledge of the correlations between generative parameters and component properties, as well as of the interdependency between the additive process and the subsequent machining process to tune the former to the latter was essential. To ascertain this behaviour, a suitable test part was designed to perform both additive processes using laser metal wire deposition with a closed loop control of the track height and subtractive processes using external and internal longitudinal turning with varied parameters. The so manufactured test parts were then used to qualify the material deposition and turning process by criteria like shape accuracy and surface quality.

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OCT sensor for layer height control in DED using SINUMERIK® controller

Cited by 11 publications

References 0 publications

Laser Metal Deposition with Coaxial Wire Feeding for the Automated and Reliable Build-Up of Solid Metal Parts

Laser Metal Deposition with Coaxial Wire Feeding for the Automated and Reliable Build-Up of Solid Metal Parts

Laser welding in e-mobility: process characterization and monitoring

Influence of a closed-loop controlled laser metal wire deposition process of S Al 5356 on the quality of manufactured parts before and after subsequent machining

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