Multiphysics Modeling, Sensitivity Analysis, and Optical Performance Optimization for Optical Laser Head in Additive Manufacturing
Source abstract
Abstract
Optical laser head is a key component used to shape the laser beam and to deliver higher power laser irradiation onto workpieces for material processing. A focused laser beam size and optical intensity need to be controlled to avoid decreasing beam quality and loss of intensity in laser material processing. This paper reports the multiphysics modeling of an in-house developed laser head for laser-aided additive manufacturing (LAAM) applications. The design of computer experiments (DoCE) combined with the response surface model was used as an efficient design approach to optimize the optical performance of a high power LAAM head. A coupled structural-thermal-optical-performance (STOP) model was developed to evaluate the influence of thermal effects on the optical performance. A number of experiments with different laser powers, laser beam focal plane positions, and environmental settings were designed and simulated using the STOP model for sensitivity analysis. The response models of the optical performance were constructed using DoCE and regression analysis. Based on the response models, optimal design settings were predicted and validated with the simulations. The results show that the proposed design approach is effective in obtaining optimal solutions for optical performance of the laser head in LAAM.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Laser Material Processing Techniques · Additive Manufacturing Materials and Processes · Welding Techniques and Residual Stresses
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Singapore Institute of Manufacturing Technology, 73 Nanyang Drive, Singapore 637662, Singapore
School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore
References (30)
Show source-provided references
1. Optics to control thermal effects in selective laser melting
2. Louca, R.G., Yannis, K., Jean-Pierre, K., and Brecht, V.H. (2018, January 13–15). On the influence of thermal lensing during selective laser melting. Proceedings of the 29th Annual International Solid Freeform Fabrication Symposium, Austin, TX, USA.
3. Analysis of influence of thermally induced aberrations on laser beam quality factor (M2) in a high-power laser system
4. Thiel, C., Stubenvoll, M., Schäfer, B., and Krol, T.A. (2015). Reliable beam positioning for metal-based additive manufacturing by means of focal shift reduction. Macro Processing: Additive Manufacturing, WLT.
5. Influence of thermally induced aberrations on resulting intensity distribution
6. Structural-Thermal-Optical-Performance (STOP) analysis for the prediction of the line-of-sight stability of JANUS camera on board JUICE ESA mission
7. Development and implementation of a generic analysis template for structural-thermal-optical-performance modeling10.1117/12.2236427 ↗
8. Structural, thermal, and optical performance (STOP) modeling and results for the James Webb Space Telescope integrated science instrument module
9. Structural, Thermal, and Optical Performance (STOP) analysis of the NASA ARCSTONE instruments
10. Multi-physical analysis of thermo-optical effects for different Selective Laser Melting (SLM) scanning strategies10.1016/j.procir.2018.08.048 ↗
11. Borror, C.M. (1998). Response Surface Methods for Experiments Involving Noise Variables, UMI.
12. Gunst, R.F., Myers, R.H., and Montgomery, D.C. (1995). Response Surface Methodology: Process and Product Optimization Using Designed Experiments, John Wiley and Sons.10.2307/1270613 ↗
13. Khuri, A.I., and Cornell, J.A. (1996). Response Surfaces: Design and Analyses, Marcel Dekker. [2nd ed.].
14. Optimization of different welding processes using statistical and numerical approaches—A reference guide10.1016/j.advengsoft.2007.03.012 ↗
15. Optimization of laser cutting processes using design of experiments10.1016/j.phpro.2010.08.050 ↗
16. Madrid, J., Lorin, S., Söderberg, R., Hammersberg, P., Wärmefjord, K., and Lööf, J. (2019). A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications. Aerospace, 6.10.3390/aerospace6060074 ↗
17. IN100 Ni-based superalloy fabricated by micro-laser aided additive manufacturing: Correlation of the microstructure and fracture mechanism10.1016/j.msea.2020.139467 ↗
18. Characterization of wear properties of the functionally graded material deposited on cast iron by laser-aided additive manufacturing10.1007/s00170-019-03414-w ↗
19. Restoration of Nickel-Base Turbine Blade Knife-Edges with Controlled Laser Aided Additive Manufacturing10.1016/j.phpro.2011.03.051 ↗
20. Excellent combination of strength and ductility of CoCrNi medium entropy alloy fabricated by laser aided additive manufacturing
21. Chen, L., Yao, X., Xu, P., Moon, S.K., and Bi, G. (2020). Rapid surface defect identification for additive manufacturing with in-situ point cloud processing and machine learning. Virtual Phys. Prototyp., 1–18.10.1080/17452759.2020.1832695 ↗
22. Laser metal deposition with spatial variable orientation based on hollow-laser beam with internal powder feeding technology10.1016/j.optlastec.2016.09.019 ↗
23. Laser rapid manufacturing on vertical surfaces: Analytical and experimental studies10.1016/j.surfcoat.2013.02.044 ↗
24. An overview of Direct Laser Deposition for additive manufacturing; Part I: Transport phenomena, modeling and diagnostics
25. A novel approach to fabricate uni-directional and branching slender structures using laser-based direct metal deposition10.1016/j.ijmachtools.2006.08.012 ↗
26. Hammeke, A.W. (1988). Laser Spray Nozzle and Method. (4,724,299), U.S. Patent.
27. Sato, A., Ishikawa, Y., Nowotny, S., and Scharek, S. (2009). Powder Metal Cladding Nozzle. (7,626,136), U.S. Patent.
28. Guo, W. (2007). Compact Coaxial Nozzle for Laser Cladding. (7,259,353), U.S. Patent.
29. (2019). Data and Properties Optics Fused Silica, Heraeus Quarzglas GmbH & Co. KG.
30. Incropera, F., and DeWitt, D. (1985). Fundamentals of Heat and Mass Transfer, John Wiley. [2nd ed.].