On-the-fly control of laser additive manufacturing

激光增材制造的动态控制

• 批准号: 463305-2014
• 负责人: Fraser, James
• 金额: $ 9.09万
• 依托单位: Queen's University
• 依托单位国家: 加拿大
• 项目类别: Strategic Projects - Group
• 财政年份: 2017
• 资助国家: 加拿大
• 起止时间: 2017-01-01 至 2018-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=641876
• 关键词: fly; control; laser; additive; manufacturing

Laser additive manufacturing uses a tightly focused laser beam scanned over a precursor material (such as metal powder) to "write" a 3D metal component layer by layer, allowing the creation of lightweight designs directly from a computer drawing. Even though laser additive manufacturing is a billion dollar industry undergoing exponential growth, its widespread adoption is being impeded by lack of an in situ quality assurance technique. Solving the QA/control problem will be of key strategic importance for Canadian industry and their ability to innovate in highly competitive industries, such as automotive, aerospace and medical device manufacturing. We will exploit a novel coherent imaging technique invented in Canada to directly high-speed image the laser writing process while it is happening. In addition to providing direct quality assurance for every 3D pixel, we will use our new technology to close the feedback loop to allow on-the-fly compensation of process parameters to achieve the targeted composition. Errors will be erased as they are written. This will reduce failures and has the potential to open the door to novel geometries, writing techniques and materials currently not possible due to the inherent randomness of the laser writing process. Outcomes of this project include: i) training of nine students/researchers in a field of key important to Canadian advanced manufacturing, ii) reduction of novel component process development time, iii) novel design paradigms enabled by on-the-fly control, and iv) improved understanding of the underlying physics happening at the tip of a high power laser beam.

激光添加剂制造使用在前体材料（例如金属粉）上扫描的紧密聚焦的激光束来按一层“编写” 3D金属组件，从而可以直接从计算机图中创建轻量级设计。尽管激光添加剂制造业是一个经历了指数增长的十亿美元行业，但由于缺乏原位质量保证技术而阻碍了广泛的采用。解决质量检查/控制问题对于加拿大工业及其在高度竞争性行业（例如汽车，航空航天和医疗设备制造）中创新的能力将具有关键的战略重要性。我们将利用在加拿大发明的一种新颖的连贯成像技术，以直接在激光器编写过程中直接图像。除了为每3D像素提供直接的质量保证外，我们还将使用新技术来关闭反馈循环，以允许流程参数的赔偿以实现目标构图。错误将被删除。这将减少失败，并有可能为新的几何形状，由于激光写作过程的固有随机性而无法进行新的几何形状，编写技术和材料。该项目的结果包括：i）在一个对加拿大高级制造业的关键领域中对九名学生/研究人员进行培训，ii）减少新型组件过程开发时间，iii）新型的设计范式，通过在现场控制中启用了新的设计范式，iv）提高了对高功率激光束的底层物理学的了解。