On-the-fly laser beam shaping for Laser Metal Deposition of crack-sensitive Al-Ti alloys - ShapeAM

Project summary

The objective is to use a novel CBC OPA fiber laser for AM. The CBC OPA fiber will create unlimited beam shapes and scanning patterns.This fast laser beam shaping tool enables unprecedented modifiable intensity distributions for enhanced control of melt pool shape, size and dynamics that will improve processing: reduction of cracking, a distortion-low and near net shape build-up process, reduced part surface roughness and the capability to process critical and new materials. Potential applications are numerous and in all branches (medicine, energy but especially aerospace and space). A model will be developed on how fast laser beam shaping can be translated into manufacturing strategies.CBC OPA fiber laser will be used in an experimental approach to demonstrate how beam shaping is able to improve the AM process.LMD with testing on critical materials like crack-sensitive Al and Ti alloys is the focus. A novel printer will be designed and constructed. As a result, ShapeAM will reach TRL4