Massively parallel laser arrays for high-throughput selective laser melting of Inconel 718 super alloy
Abstract
The goal of Additive Manufacturing (AM) is to reduce raw material usage, reduce lead time for part production, and/or manufacturing cost while maintaining or improving the performance of the part. AM is applicable to various material systems but is of particular interest to produce high-cost, metallic aerospace components with long lead-times. Selective laser melting (SLM) technology has shown much promise although long process times and process defects are problematic. All existing commercial SLM systems utilise single point lasers for powder consolidation through direct melt pool generation. Increases in productivity have been attained through the use multiple laser/scanner combinations. The fundamental problem with single point laser melting of powder beds is the lack of melt pool stability. Significant volatility occurs when melting powder beds due effects such as vaporisation, Marangoni convection, powder displacement, thermal plumes, and rapid solidification effects that lead to the formation of trapped pores, voids, inclusions, and cracking [1]. These defects are particularly troubling for aerospace applications, limiting some crucial performances such as fatigue. Fatigue performance is the key attribute for a process to be applied on an aircraft, since it directly limits part lifetime and possibility of failure for a single part [2,3].
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Apr 20, 2023
- Source ID
- FA86552217166
Entities
People
- William O Neill
Organizations
- Air Force Office of Scientific Research
- United States Air Force
- University of Cambridge