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.
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