Physics Procedia 

Abstract: Selective Laser Melting (SLM) is an Additive Manufacturing (AM) technique in which a part is built up in a layer- by-layer manner by melting the top surface layer of a powder bed with a high intensity laser according to sliced 3D CAD data. In this work, mechanical properties like tensile strength, elongation, Young's modulus, impact toughness and hardness are investigated for SLM-produced AlSi10Mg parts, and compared to conventionally cast AlSi10Mg parts. It is shown that AlSi10Mg parts with mechanical properties comparable or even exceeding to those of conventionally cast AlSi10Mg can be produced by SLM.

Abstract: Selective Laser Melting (SLM) is one of the Additive Manufacturing (AM) technologies that enables the production of light weight structured components with series identical mechanical properties without the need for part specific tooling or downstream sintering processes, etc. Especially aluminum is suited for such eco-designed components due to its low weight and superior mechanical and chemical properties. However, SLM's state-of-the-art process and cost efficiency is not yet suited for series-production. In order to improve this efficiency it is indispensable to increase the build rate significantly. Thus, aluminum is qualified for high build rate applications using a new prototype machine tool including a 1 kW laser and a multi-beam system.

Abstract: Selective Laser Melting (SLM) is an Additive Manufacturing process in which a part is built in a layer by layer manner. A laser source selectively scans the powder bed according to the CAD data of the part to be produced. The high intensity laser beam makes it possible to completely melt the metal powder particles to obtain almost fully dense parts. In this work, the influence of process parameters in SLM (e.g. scan speed and layer thickness) and various age hardening treatments on the microstructure and mechanical properties of 18Ni-300 steel is investigated. It is shown that almost fully dense parts with mechanical properties comparable to those of conventionally produced maraging steel 300 can be produced by SLM.

Abstract: In laser microstructuring there is a general conflict between precision and efficiency. Short pulsed micro- and nanosecond systems generally allow high ablation rates. Yet, thermal damage of the workpiece cannot be avoided completely. Ultrafast picoand femtosecond systems allow a higher precision, yet at lower ablation efficiency. This on the one hand can be attributed to the generally lower medium laser power of the ultrafast laser systems, on the other hand to the changed ablation mechanisms. In this contribution a comparative study of the ablation of metal with micro-, nano-, pico- and femtosecond laser pulses shall be presented.

Abstract: Laser Additive Manufacturing (LAM) enables economical production of complex lightweight structures as well as patient individual implants. Due to these possibilities the additive manufacturing technology gains increasing importance in the aircraft and the medical industry. Yet these industries obtain high quality standards and demand predictability of material properties for static and dynamic load cases. However, especially fatigue and crack propagation properties are not sufficiently determined. Therefore this paper presents an analysis and simulation of crack propagation behavior considering Laser Additive Manufacturing specific defects, such as porosity and surface roughness. For the mechanical characterization of laser additive manufactured titanium alloy Ti-6Al-4V, crack propagation rates are experimentally determined and used for an analytical modeling and simulation of fatigue. Using experimental results from HCF tests and simulated data, the fatigue and crack resistance performance is analyzed considering material specific defects and surface roughness. The accumulated results enable the reliable prediction of the defects influence on fatigue life of laser additive manufactured titanium components.