Fakultät Maschinenbau
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In former works, the optical material properties of different polymer powders used for Laser Beam Melting (LBM) at room temperature have been analyzed. With a measurement setup using two integration spheres, it was shown that the optical material properties of polymer powders differ significantly due to multiple reflections within the powder compared to solid bodies of the same material. Additionally, the absorption behavior of the single particles shows an important influence on the overall optical material properties, especially the reflectance of the powder bed. Now the setup is modified to allow measurements at higher temperatures. Because crystalline areas of semi-crystalline thermoplastics are mainly responsible for the absorption of the laser radiation, the influence of the temperature increase on the overall optical material properties is analyzed. As material, conventional polyamide 12 and polypropylene as new polymer powder material, is used. By comparing results at room temperature and at higher temperatures towards the melting point, the temperature-dependent optical material properties and their influence on the beam-matter interaction during the process are discussed. It is shown that the phase transition during melting leads to significant changes of the optical material properties of the analyzed powders.
Purpose – The purpose of this paper is to demonstrate the processability of cohesive PE-HD particles in laser beam melting processes (LBM) of polymers. Furthermore, we present a characterization method for polymer particles, which can predict the quality of the powder deposition via LBM processes. Design/methodology/approach – This study focuses on the application of dry particle coating processes to increase flowability and bulk density of PE-HD particles. Both has been measured and afterwards validated via powder deposition of PE-HD particles in a LBM machine. Findings – For efficient coating in a dry particle coating process, the PE-HD particles and the attached nanoparticles need to show similar surface chemistry, i.e. both need to behave either hydrophobic or hydrophilic. It is demonstrated that dry particle coating is appropriate to enhance flowability and bulk density of PE-HD particles and hence considerably improves LBM processes and the resulting product quality. Originality/value – At present, in LBM processes mainly polyamide (PA), 12 particles are used, which are so far quite expensive in comparison to, for example, PE-HD particles. This work provides a unique and versatile method for nanoparticulate surface modification which may be applied to a wide variety of materials. After the coating, the particles are applicable for the LBM process. Our results provide a correlation between flowability and bulk density and the resulting product quality.
Comparison between the optical properties of injection molded and additive manufactured components
(2018)
Fused Layer Manufacturing (FLM) is an additive technology based on polymer material extrusion. Due to variations in temperature during the manufacturing process and the resulting stress between the stacked layers, the final parts show anisotropic mechanical properties. One possible approach for their reduction is the immediate local preheating of the surface via laser radiation. At first, our research examines the influence of laser parameters as wavelength, power, velocity and area of impact for the preheating of the surface. In addition, an overview of possible parameter combinations is given based on the selection of raw materials, its colors, thicknesses and the manufacturing process. Initially, the absorption level of the materials regarding the emitted wavelength is detected using a spectrophotometer. Subsequently, preheating tests are conducted with different laser types while the temperature is determined by a thermal camera. The selected laser type is planned to get mounted on a prototype-machine for further in-situ preheating experiments on FLM parts during the manufacturing process.
Experimental and mathematical characterization of coronary polyamide-12 balloon catheter membranes
(2020)
The experimental quantification and modeling of the multiaxial mechanical response of polymer membranes of coronary balloon catheters have not yet been carried out. Due to the lack of insights, it is not shown whether isotropic material models can describe the material response of balloon catheter membranes expanded with nominal or higher, supra-nominal pressures. Therefore, for the first time, specimens of commercial polyamide-12 balloon catheters membranes were investigated during uniaxial and biaxial loading scenarios. Furthermore, the influence of kinematic effects on the material response was observed by comparing results from quasi-static and dynamic biaxial extension tests. Novel clamping techniques are described, which allow to test even tiny specimens taken from the balloon membranes. The results of this study reveal the semi-compliant, nonlinear, and viscoelastic character of polyamide-12 balloon catheter membranes. Above nominal pressure, the membranes show a pronounced anisotropic mechanical behavior with a stiffer response in the circumferential direction. The anisotropic feature intensifies with an increasing strain-rate. A modified polynomial model was applied to represent the realistic mechanical response of the balloon catheter membranes during dynamic biaxial extension tests. This study also includes a compact set of constitutive model parameters for the use of the proposed model in future finite element analyses to perform more accurate simulations of expanding balloon catheters.
Quasi-simultaneous laser transmission welding is a well-known joining technique for thermoplastics and mainly used in the automotive as well as in the medical industry. For process control usually the so called set-path monitoring is used, where the weld is specified as "good" if the irradiation time is inside a defined confidence interval. However, the detection of small-sized gaps or thermal damaged zones is not possible with this technique. The analyzation of the weld seam temperature during welding offers the possibility to overcome this problem. In this approach a 3D-scanner is used instead of a scanner with flat-field optic. By using a pyrometer in combination with a 3D-scanner no color-corrected optic is needed in order to provide that laser- and detection-spot are concentric. Experimental studies on polyethylene T-joints have shown that the quality of the signal is adequate, despite the use of an optical setup with a long working distance and a small optical aperture. The effects on temperature are studied for defects like a gap in the joining zone. Therefore a notch was milled into the absorbent polymer. In case of producing housings for electronic parts the effect of an electrical wire between the joining partners is also investigated. Both defects can be identified by a local temperature deviation even at a feed rate of four meters per second. Furthermore a strategy for signal-processing is demonstrated. By this, remaining defects can be identified. Consequently an online detection of local defects is possible, which makes a dynamic process control feasible.