Abstract
Abstract Additively manufactured parts typically deviate to some extent from the targeted net shape and exhibit high surface roughness due to the size of the powder grains that determines the minimum thickness of the individual slices and due to partially molten powder grains adhering on the surface. Optical coherence tomography (OCT)-based measurements and closed-loop controlled ablation with ultrashort laser pulses were utilized for the precise positioning of the LPBF-generated aluminum parts and for post-processing by selective laser ablation of the excessive material. As a result, high-quality net shape geometries were achieved with surface roughness, and deviation from the targeted net shape geometry reduced by 67% and 63%, respectively.
Highlights
Additive manufacturing comprises a wide range of different manufacturing processes
Additively manufactured parts typically deviate to some extent from the targeted net shape and exhibit high surface roughness due to the size of the powder grains that determines the minimum thickness of the individual slices and due to partially molten powder grains adhering on the surface
Optical coherence tomography (OCT)-based measurements and closed-loop controlled ablation with ultrashort laser pulses were utilized for the precise positioning of the laser powder bed fusion (LPBF)-generated aluminum parts and for post-processing by selective laser ablation of the excessive material
Summary
Additive manufacturing comprises a wide range of different manufacturing processes. With laser powder bed fusion (LPBF) complex, metallic parts are generated from slices of selectively molten powder. We present OCT-based closed-loop controlled laser ablation of LPBF-generated aluminum parts with ultrashort laser pulses in order to reduce the surface roughness and improve the geometrical accuracy. The OCT-based measurements were used for both the precise positioning of the workpiece and to determine the areas where further ablation is required to reach the targeted net shape of the additively produced parts This approach combines the advantages of additive and subtractive laser manufacturing processes in order to create 3D-shaped geometries with high freedom of design and high precision. The presented approach is evaluated with regard to the removal of surface defects and the achievable accuracy of manufacturing different geometries
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