Although powder-based additive manufacturing processes have great potential for the toolless production of complex and individual components with almost unlimited design freedom, they have only hesitantly been used for the flexible production of individual workpieces. One reason for this is the unacceptable quality deficits in terms of geometrical accuracy and component strength. In the case of selective laser melting (SLM), these are induced not only by component distortion during cooling, but also by fluctuations in the process parameters and influencing factors such as laser energy, layer thickness, particle size, temperature history, and relative position deviations between the laser beam and the powder bed caused during layer-by-layer production. Detection of warpage using retained samples and special test specimens is expensive and potentially inaccurate due to the correlation between part properties and position in the building chamber resulting from spatial temperature gradient dependencies [6]. As a workaround, a layer-wise incremental in-line measurement has to be carried out. The automatic correction of process fluctuation-related component errors through the regulation of process parameters that can be realized with this should allow a significant reduction in rejects, costs, and provision times.

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Geometric Measurement and Testing Technology for Additive Manufacturing

  • Benjamin Baumgärtner,
  • Tino Hausotte

摘要

Although powder-based additive manufacturing processes have great potential for the toolless production of complex and individual components with almost unlimited design freedom, they have only hesitantly been used for the flexible production of individual workpieces. One reason for this is the unacceptable quality deficits in terms of geometrical accuracy and component strength. In the case of selective laser melting (SLM), these are induced not only by component distortion during cooling, but also by fluctuations in the process parameters and influencing factors such as laser energy, layer thickness, particle size, temperature history, and relative position deviations between the laser beam and the powder bed caused during layer-by-layer production. Detection of warpage using retained samples and special test specimens is expensive and potentially inaccurate due to the correlation between part properties and position in the building chamber resulting from spatial temperature gradient dependencies [6]. As a workaround, a layer-wise incremental in-line measurement has to be carried out. The automatic correction of process fluctuation-related component errors through the regulation of process parameters that can be realized with this should allow a significant reduction in rejects, costs, and provision times.