Beam Shaping: Enhancing Cost-to-Value in L-PBF.
In a variety of research projects, improvements in process efficiency through the use of laser beam shaping have been demonstrated. At Fraunhofer IAPT, we draw on extensive experience with different systems. By employing partially dynamic beam adjustments, we can enhance melt pool stability, which significantly boosts productivity and reduces unwanted byproducts, such as spatter and smoke.
Advantages of Laser Beam Shaping
Laser Powder Bed Fusion (L-PBF) is the industry-preferred method for producing geometrically complex metal components in substantial volumes. However, industries are seeking enhancements in productivity and process stability while reducing the high costs associated with this technology. Laser beam shaping effectively addresses these challenges.
Due to a more homogeneous energy input into the melt pool, it is possible to avoid evaporation effects and to use almost the entire laser energy within the process zone for material deposition. Figure 1 shows three commonly used beam shapes. It qualitatively compares the different intensity and temperature profiles, as well as the melting areas in the cross-section.
A Gaussian-shaped laser beam profile introduces too much energy into the melt pool in the center, whereas it is barely sufficient for melting in the edge area. A ring-shaped beam profile, on the other hand, ensures an even distribution of temperature. It prevents evaporation effects and enhances productivity and process stability.
