Universität Stuttgart
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Item Open Access Tuning the hardness of produced parts by adjusting the cooling rate during laser-based powder bed fusion of AlSi10Mg by adapting the process parameters(2022) Leis, Artur; Traunecker, David; Weber, Rudolf; Graf, ThomasThe mechanical properties of parts produced by laser-based powder bed fusion (LPBF) are mainly determined by the grain structure in the material, which is governed by the cooling rate during solidification. This cooling rate strongly depends on the scan velocity and the absorbed laser power. Experiments with varying process parameters were performed to develop and validate an analytical model that predicts the hardness of printed AlSi10Mg parts. It was found that it is possible to tune the hardness of additively manufactured parts of AlSi10Mg in a range between 60 ± 9 HV0.5 and 100 ± 10 HV0.5 by adjusting the cooling rate during solidification with adapted process parameters.Item Open Access Data-driven prediction and uncertainty quantification of process parameters for directed energy deposition(2023) Hermann, Florian; Michalowski, Andreas; Brünnette, Tim; Reimann, Peter; Vogt, Sabrina; Graf, ThomasLaser-based directed energy deposition using metal powder (DED-LB/M) offers great potential for a flexible production mainly defined by software. To exploit this potential, knowledge of the process parameters required to achieve a specific track geometry is essential. Existing analytical, numerical, and machine-learning approaches, however, are not yet able to predict the process parameters in a satisfactory way. A trial-&-error approach is therefore usually applied to find the best process parameters. This paper presents a novel user-centric decision-making workflow, in which several combinations of process parameters that are most likely to yield the desired track geometry are proposed to the user. For this purpose, a Gaussian Process Regression (GPR) model, which has the advantage of including uncertainty quantification (UQ), was trained with experimental data to predict the geometry of single DED tracks based on the process parameters. The inherent UQ of the GPR together with the expert knowledge of the user can subsequently be leveraged for the inverse question of finding the best sets of process parameters by minimizing the expected squared deviation between target and actual track geometry. The GPR was trained and validated with a total of 379 cross sections of single tracks and the benefit of the workflow is demonstrated by two exemplary use cases.Item Open Access Friction and wear behavior of deep drawing tools using volatile lubricants injected through laser-drilled micro-holes(2021) Reichardt, Gerd; Henn, Manuel; Reichle, Paul; Umlauf, Georg; Riedmüller, Kim; Weber, Rudolf; Barz, Jakob; Liewald, Mathias; Graf, Thomas; Tovar, Günter E. M.In deep drawing processes, the use of lubricants is mandatory in order to prevent wear on tools and surface damage to the formed sheet metal components. Here, frequently used lubricants are synthetic and mineral oils, emulsions, and waxes. However, these conventional lubricants have to be applied to the sheet material prior to the forming operation and removed afterwards by cleaning processes. Additionally, the lubricants often contain substances that are harmful to the environment and to human health. To counteract these economic and ecological disadvantages, research is currently being conducted on a novel tribological system. For this, volatile media such as liquid carbon dioxide and gaseous nitrogen are being used, and are introduced directly into the friction zones between the tool and the sheet metal material during deep drawing under high pressure through special laser-drilled micro-holes. This paper covers the latest investigations and findings regarding the design of flow-optimized micro-holes, the laser drilling process, the friction characterization on tool radii, and the tool wear to be expected when using the lubrication medium CO2.Item Open Access 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(2021) Becker, Dina; Boley, Steffen; Eisseler, Rocco; Stehle, Thomas; Möhring, Hans-Christian; Onuseit, Volkher; Hoßfeld, Max; Graf, ThomasThis 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.Item Open Access Supercritical melt flow in high-speed laser welding and its interdependence with the geometry of the keyhole and the melt pool(2024) Reinheimer, Eveline N.; Berger, Peter; Hagenlocher, Christian; Weber, Rudolf; Graf, ThomasThe advent of undercuts and humping limits the applicable speed of deep-penetration laser welding. Recent findings additionally show that a significant change of the keyhole’s shape is associated with the occurrence of undercuts. Considering that undercuts and humping are melt flow–induced defects, this leads to the question of how the geometry of the keyhole and the melt pool influence the melt flow and vice versa. In this work, the Froude number was used to characterize the melt flow around a keyhole. X-ray images of the keyhole and cross-sections of the weld were therefore used to determine the geometrical boundaries of the melt flow, to estimate the average melt velocity around the keyhole, and finally determine its Froude number. The flow around a cylindrically shaped keyhole was found to always be subcritical, whereas supercritical melt flow was observed around the elongated keyholes that are formed at higher welding speed. The findings may be interpreted in the sense that the elongation of the keyhole is a consequence of a supercritical stream of the melt flowing underneath and around the keyhole. This perception is consistent with the long-known experience that humping may be avoided by reducing the flow speed of the melt by widening the melt pool surrounding the keyhole (e.g., by means of beam shaping) and suggest a new explanation for the elongation of the keyhole at increased welding speed.Item Open Access First thin-disk oscillator with ceramic Yb:LuScO3 in comparison to the operation with ceramic Yb:Lu2O3(2024) Esser, Stefan; Jing, Wei; Xu, Xiaodong; Graf, Thomas; Abdou Ahmed, MarwanWe report on the characterization and first laser operation of ceramic Yb:LuScO3 in a thin-disk oscillator. The optical performance achieved with a ceramic Yb:LuScO3 disk is compared to the one obtained with an existing ceramic Yb:Lu2O3 disk for reference. The characterization covers the measurement of the fluorescence spectra, the fluorescence lifetimes, and nomarsky imaging. The investigation on the laser operation covers the measurement of resonator losses, output powers, and thermal behavior during continuous-wave operation in a multimode thin-disk oscillator. An average output power of 149 W and a slope efficiency of 51.8% were achieved with the ceramic Yb:LuScO3 disk which reached a maximum surface temperature of about 150 °C. At the same temperature level, a disk made of the already established ceramic Yb:Lu2O3 delivered 957 W of output power with a slope efficiency of 75.7%.Item Open Access High-speed single-frame polarimeter for thermal radiation to measure the 3D geometry of hot metal surfaces(2024) Sawannia, Michael; Berger, Peter; Weber, Rudolf; Hagenlocher, Christian; Graf, ThomasThe 3D geometry of the interaction zone in laser material processing is of major importance as it defines the absorption of the laser beam and may influence the hydrodynamics of the process. With the aim of measuring this geometry, which typically changes with frequencies in the order of 10 kHz, a single-frame polarimeter with acquisition rates of up to 75 kHz is presented in this work. It simultaneously records four images of the thermal process emission, through four linear polarizers with different orientations. The formulae required for the reconstruction of the 3D geometry from these images are derived and validated on an example of a heated steel sphere. The reconstructed geometry was found to be in good agreement with the examined sphere. An experimental example is also given of the application of this technology to geometry measurement of a highly dynamic laser cutting front at a framerate of 75 kHz.Item Open Access Adjustment of the geometries of the cutting front and the kerf by means of beam shaping to maximize the speed of laser cutting(2023) Lind, Jannik; Hagenlocher, Christian; Weckenmann, Niklas; Blazquez-Sanchez, David; Weber, Rudolf; Graf, ThomasThe shape of the laser beam used for fusion cutting significantly influences the geometry of both the cutting front and the cutting kerf. The angle of the cutting front in turn impacts the local absorptivity, while the width of the kerf defines the amount of material, which has to be molten. The kerf’s geometry therefore determines the maximum possible cutting speed at which a successful cut is feasible with a given available laser power. The absorptivity, the width of the kerf, and the maximum possible cutting speed can be estimated from a simple model considering the conservation of energy and rough geometrical approximations. In order to verify the prediction of the model, the geometry of the cutting front and kerf resulting from different processing conditions was observed by means of online high-speed X-ray diagnostics. The geometry of the interaction zone was recorded with a framerate of 1000 Hz during fusion cutting of 10-mm-thick samples of stainless steel. Comparing the results obtained with different shapes of the laser beam, it was found that the absorptivity is increased when the beam’s longitudinal cross-section (parallel to the feed) is enlarged. Reducing the width of the beam in the transversal direction normal to the feed reduces the cross-sectional area of the cutting kerf. The findings show a good agreement with the geometric model which enabled the prediction of the absorptivity and the cross-sectional area of the cutting kerf and hence allows to reliably estimate the maximum cutting speed for different shapes of the laser beam, laser power, and sheet thicknesses.