Additive manufacturing of quartz glass using coaxial wire feeding technology

Abstract

This study explores the process of coaxial wire feeding and melting for quartz additive manufacturing using Direct Energy Deposition (DED). Quartz glass, valued for its excellent mechanical, optical, and thermal properties, is widely used in semiconductor, aerospace, and optical communication industries. Additive manufacturing offers advantages such as cost-effective materials, rapid formation, and customization of structures. However, current methods for additive manufacturing of quartz glass often result in low quality or require complex post-processing, particularly for optical components. In optics, there is a demand for high-quality, straightforward processes, and custom-shaped quartz glass. This article presents a coaxial wire feeding mechanism wherein quartz wire is fed vertically downward along the optical axis into the melting zone created by a CO2 laser, facilitating smooth material deposition onto the molten zone’s surface. Laser power, wire feeding speed, substrate movement speed, and defocusing distance are key factors influencing the quality of single-layer quartz glass formation. Positive defocusing was found to have a beneficial impact on single-layer quartz glass additive manufacturing. Subsequently, optimized process parameters enabled the production of uniformly cross-sectional single-layer quartz glass. Microscopic morphology analysis and temperature field simulation were conducted on the experimental results before and after optimization. Finally, complex quartz glass structures were additively manufactured using the optimized experimental parameters. Results demonstrate that coaxial wire feeding technology has significant potential for achieving uniform dimensions and complex structures in quartz glass additive manufacturing.