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Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and Micromilling
(2021)
We report on a comprehensive study to evaluate fundamental properties of a hybrid
manufacturing approach, combining selective laser melting and high speed milling, and to characterize
typical geometrical features and conclude on a catalogue of design rules. As for any additive
manufacturing approach, the understanding of the machine properties and the process behaviour as
well as such a selection guide is of upmost importance to foster the implementation of new machining
concepts and support design engineers. Geometrical accuracy between digitally designed and
physically realized parts made of maraging steel and dimensional limits are analyzed by stripe line
projection. In particular, we identify design rules for numerous basic geometric elements like walls,
cylinders, angles, inclinations, overhangs, notches, inner and outer radii of spheres, chamfers in build
direction, and holes of different shape, respectively, as being manufactured by the hybrid approach
and compare them to sole selective laser melting. While the cutting tool defines the manufacturability
of, e.g., edges and corners, the milling itself improves the surface roughness to Ra < 2 µm. Thus,
the given advantages of this hybrid process, e.g., space-resolved and custom-designed roughness
and the superior geometrical accuracy are evaluated. Finally, we exemplify the potential of this
particular promising hybrid approach by demonstrating an injection mold with a conformal cooling
for a charge socket for an electro mobile
We report on milling and tool wear characteristics of hybrid additive manufacturing comprising laser powder bed fusion and in situ high-speed milling, a particular process in which the cutter mills inside the powder bed without any cooling lubricant being applicable. Flank wear is found to be the dominant wear characteristic with its temporal evolution over utilization period revealing the typical s-shaped dependence. The flank wear land width is measured by microscopy and correlated to the achievable surface roughness of milled 3D-printed parts, showing that for flank wear levels up to 100 μm a superior surface roughness below 3 μm is accessible for hybrid additive manufacturing. Further, based on this correlation recommended tool, life scenarios can be deduced. In addition, by optimizing the finishing tool start position and the number of afore-built layers, the milling process is improved with respect to the maximum millable angle for undercut surfaces of 3D-printed parts to 30° for the roughing process and to 40° for the entire machining process including finishing
Sapphire is a robust and wear-resistant material. However, efficient and high-quality micromachining is still a challenge. This contribution demonstrates and discusses two novels, previously unreported approaches for femtosecond laser-based micromachining of rotational-symmetric sapphire workpieces, whereas both methods are in principal hybrids of laser scanning and laser turning or laser lathe. The first process, a combination of a sequential linear hatch pattern in parallel to the workpiece’s main axis with a defined incremental workpiece rotation, enables the fabrication of sapphire fibers with diameters of 50 µm over a length of 4.5 mm. Furthermore, sapphire specimens with a diameter of 25 µm over a length of 2 mm can be fabricated whereas an arithmetical mean height, i.e., Sa parameter, of 281 nm is achieved. The second process combines a constant workpiece feed and orthogonal scanning with incremental workpiece rotation. With this approach, workpiece length limitations of the first process are overcome and sapphire fibers with an average diameter of 90 µm over a length of 20 cm are manufactured. Again, the sapphire specimen exhibits a comparable surface roughness with an average Sa value of 249 nm over 20 cm. Based on the obtained results, the proposed manufacturing method paves an innovative and flexible, all laser-based way towards the fabrication or microstructuring of sapphire optical devices, and thus, a promising alternative to chemical processes.
This contribution quantifies the birefringence within injection-molded cyclic olefin copolymer plates and discusses its impact on the mechanical properties of the plates. It also focuses on the impact of birefringence on integrated waveguides and Bragg gratings and provides fabrication guidelines for such structures. The anisotropy in all three dimensions of the workpiece is examined by means of polarimetry and a prism coupler. It is found that the birefringence is inhomogenously distributed within the workpieces, whereas the maximum birefringence not only varies locally, but also depends on the observation direction. Overall, a maximum birefringence of 10 × 10−4 is found at the plate’s surface near the injection gate. The anisotropy then reduces exponentially towards the center of the workpiece and saturates at 1.8 × 10−4, in a depth of 0.4 mm. Thus, the birefringence strongly affects near-surface photonic structures. It is found that, depending on their orientation and the local birefringence of the substrate, waveguides and Bragg gratings fabricated with comparable parameters behave completely differently in terms of polarization-dependent optical attenuation, cross-sectional intensity distribution and Bragg reflection signal. For example, the support of the TM mode can vary between total loss and an optical attenuation of 0.9 dB × cm−1. In consequence, this study underlines the importance of quantifying the birefringent state of an injection-molded cyclic olefin copolymer workpiece if it is supposed to serve as a substrate for integrated photonic structures. The study furthermore demonstrates that birefringence effects can be omitted by burying the photonic structures deeper into the volume of the thermoplastic.
We report on a comprehensive study of laser percussion microvia drilling of Ajinomoto build-up film (ABF) material using an ultrashort pulsed laser in MHz burst mode. After laser processing, microvia drilling quality is being evaluated by the fabricated diameter and taper using laser scanning microscopy and metallography. The influences of the incubation effect, heat accumulation and shielding effects as a result of pulse to pulse interactions are being discussed on the ablation threshold, penetration depth and laser microvia drilling quality. We find that an increasing heat accumulation in MHz burst mode processing is responsible for the void formation and delamination of the insulating ABF layer. Therefore, the parameter clearance is introduced to evaluate these effects on the microvia sidewalls. For a comparable clearance, applying 2 intra-burst pulses achieves an average reduced taper of down to 19.5% compared to single pulse mode. At the same time, a reduced laser drilling time of 16.7% per microvia highlights the enormous potential of the MHz burst mode for laser drilling of ABF material in printed circuit board fabrication.
This article proposes and demonstrates a robust microstructure-based fiber-to-chip coupling scheme for planar Bragg grating devices. A polymer planar Bragg grating substrate is manufactured and microstructured by means of a micromilling process, while the respective photonic structures are generated by employing a sophisticated single-writing UV-exposure method. A stripped standard single mode fiber is inserted into the microstructure, which is filled with a UV-curable adhesive, and aligned with the integrated waveguide. After curing, final sensor assembly and thermal treatment, the proposed coupling scheme is capable of withstanding pressures up to 10 bar, at room temperature, and pressures up to 7.5 bar at an elevated temperature of 120 °C. Additionally, the coupling scheme is exceedingly robust towards tensile forces, limited only by the tensile strength of the employed single mode fiber. Due to its outstanding robustness, the coupling scheme enables the application of planar Bragg grating devices in harsh environments. This fact is underlined by integrating a microstructure-coupled photonic device into the center of a commercial-grade carbon fiber-reinforced polymer specimen. After its integration, the polymer-based Bragg grating sensor still exhibits a reflection peak with a dynamic range of 24 dB, and can thus be employed for sensing purposes.
This contribution demonstrates and discusses electrically tunable polymer planar Bragg gratings based on bulk cyclic olefin copolymers. A lithographic single-writing-step method and femtosecond laser reductive sintering of copper(II) oxide nanoparticles are subsequently employed in order to generate buried photonic structures and copper conducting paths on top of the polymer substrate. This way, the necessary number of process steps for fabricating a planar polymer-based electro-optical device is greatly reduced. The response of a fully electrified grating structure follows temperature changes, induced by the copper conducting path, with sensitivities up to −31 pm K−1. Dilatometric measurements show that the specimen's behavior is correlated to the situationally reduced thermal expansion of the bulk polymer substrate. In consequence, the tuning response of the photonic platform follows a second order polynomial, whereas a direct current of 30 mA, which correlates to a power consumption of 18.3 mW, leads to a local temperature increase and a residual Bragg wavelength shift of 19.6 K and −547 pm, respectively. Moreover, the outstanding flexibility of the proposed fabrication concept is underlined by demonstrating alternative conducting path geometries, whereas one of the additional designs is adapted to control the spectral width of the Bragg grating's reflection peak.
This contribution discusses the integration of polymer planar Bragg grating sensors (PPBG) into carbon fiber reinforced polymer (CFRP) components. For the first time, it is shown that PPBGs based on cyclic olefin copolymers can be integrated into commercial-grade composites, thereby withstanding the demanding production processes. Pre-impregnated fibers are stacked and partially modified to form a sensor pocket. Afterwards, the CFRP specimen containing the optical sensor is cured in a heated mechanical press for 2 hours at a pressure of 7 bar and a temperature of 120 °C. A subsequent evalutaion of the sensor signal shows a Bragg wavelength shift of 1236 pm and a decline in signal amplitude of -2 dB. Three-point flexural tests of the cured sample reveal a linear behavior of the sensor signal towards external loads. The determined sensitivity in dependence of the CFRP specimen's maximum central deflection is -112 pm/mm, while correlation to the applied force results in a sensitivity of -5 pm/N.
This contribution demonstrates the functionality of polymer planar Bragg grating (PPBG) sensors integrated into commercial-grade carbon fiber reinforced polymer (CFRP) components. Multiple CFRP specimens are generated by curing a stack of pre-impregnated fibers inside of a heated mechanical press, exposing the polymer sensor to a pressure of 7 bar and a temperature of 120 °C for 2 h. After integration, the sensor still exhibits a strong and evaluable signal. Subsequent flexural experiments reveal a linear response of the integrated sensor’s Bragg wavelength to the CFRP specimen’s maximum deflection. Additional findings demonstrate that the embedded PPBG can be used to detect plastic deformations of a CFRP workpiece, whereas a linear correlation of plastic deformation to the resulting Bragg signal offset is determined. A plausibility check of the obtained results is delivered by a comparison of three-point flexural experiments on bulk CFRP workpieces, without integrated sensors and additional specimens featuring external optical sensors affixed to their surface. It is found that PPBGs based on cyclic olefin copolymers are able to overcome the temperature-related limitations of traditional polymer-based optical sensors and can thus be directly integrated into commercial-grade composites during production.
In this contribution we report on the possibilities of dry and lubricated friction modification
introduced by different laser surface texturing methods. We compare the potential of Laser-Induced
Periodic Surface Structures and Laser Beam Interference Ablation on 100Cr6 steel in a linear
reciprocating ball-on-disc configuration using 100Cr6 steel and tungsten carbide balls with load
forces between 50mN and 1000 mN. For dry friction, we find a possibility to reduce the coefficient
of friction and we observe a pronounced direction dependency for surfaces fabricated by Laser
Beam Interference Ablation. Furthermore, Laser-Induced Periodic Surface Structures result in
a load-dependent friction reduction for lubricated linear reciprocating movements. This work helps
to identify the modification behaviour of laser generated micro structures with feature sizes of
approximately 1μm and reveals new possibilities for surface engineering
In this contribution, we report on surface functionalization by introducing laser induced periodic surface structures on 100Cr6 bearing steel to modify complex tribological properties. The advanced approach of this study is the measurement of the coefficient of friction by performing a ball-on-disk Stribeck test on laser structured surfaces with polytetrafluoroethylene balls in a lubricant environment. The Stribeck test reveals the modified friction behavior using translation speeds up to 106 mm/min and load forces between 100 mN and 5000 mN. Our results show increased stiction and coefficient of friction for laser structured surfaces in the regime of boundary lubrication which is attributed to the laser induced surface asperities. Decreased coefficient of friction is observed in the regime of mixed and hydrodynamic lubrication, i.e. for velocities higher than 1000 mm/min, for surfaces covered by laser induced periodic surface structures with low spatial frequency.
We report on a comprehensive study of the mechanical properties of maraging steel
body-centred cubic lattice structures fabricated by a hybrid additive manufacturing technology that combines laser powder bed fusion with in situ high-speed milling. As the mechanical properties of additive manufactured components are inferior to, e.g., cast components, surface modifications can improve the mechanical behaviour. Different hybrid additive manufacturing technologies have been designed using additive and subtractive processes, improving process quality. Following this, mechanical testing is performed with respect to static tensile properties and dynamic stress, hardness, and porosity, comparing specimens manufactured by laser powder bed fusion only to those manufactured by the hybrid approach. In addition, the influence of different heat-treatment techniques on the mechanical behaviour of the lattice structures is investigated, namely solution and aging treatment as well as hot isostatic pressing. Thus, the influence of the superior surface quality due to the hybrid approach is evaluated, leading to, e.g., an offset of about 14–16% for the static testing of HIP lattice structures. Furthermore, the dynamic load behaviour can be improved with a finished surface, heading to a shift of the different zones of fatigue behaviour in the testing of hybrid-built specimens.