Dispersion effects of nanocomposites to improve melting and resolidification behavior during PBF-LB/P with near-infrared diode lasers

尽管如今添加剂制造工艺变得越来越流行，但可用的微粉原料往往不足以完成激光加工任务。在聚合物粉末领域，缺乏足够广泛的可加工材料，并且对材料在激光添加剂制造过程中的行为了解有限。只有通过材料科学家和工艺工程师的协作工作，才能对材料性能、工艺条件、再现性以及制造部件的性能有实质性的了解。该项目旨在提高对纳米添加剂和光束整形对近红外激光粉末床熔化(PBF-LB/P)材料加工行为影响的了解。通过使用CuS和LaB6纳米颗粒调整PA12和TPU粉末，这些纳米颗粒由可伸缩的高功率激光粉碎和下游支撑制成，将增加对PBF-NIR激光能量的吸收，从而实现光束整形选项。请注意，从传统的二氧化碳(10600 Nm)到近红外激光光源(808 Nm)的切换允许光束整形设备改进对进入加工区的能量的时间和空间控制。我们的实验装置将使用数字光处理器(DLP)在整个区域同时进行可调节的激光能量输入，以控制工艺室中的加热和冷却条件。在这一过程中，材料的微观变化预计会从宏观上影响最终零件的性能。实验将通过一个模拟模型来证实，该模型考虑了纳米添加剂材料在开发和验证后的散热和分布。因此，我们的项目包括调查与材料相关和与工艺相关的影响因素，以便通过自适应的同步近红外曝光策略为改进、可预测和可控的PBF-LB/P可调聚合物复合材料工艺铺平道路。

Even though the additive manufacturing process has become more popular these days, the available micro-powder feedstocks are often inadequate for laser processing tasks. In the field of polymer powders, there is a lack of a sufficiently wide range of processable materials and a limited understanding of the material’s behavior during laser-based additive manufacturing. A substantial understanding of the material behavior, the process conditions, the reproducibility and thus the properties of manufactured parts can only be achieved through the collaborative work of material scientists and process engineers. The proposed project aims to improve the knowledge of the influence of nano-additives and beam shaping on the material processing behavior in laser-based powder bed fusion (PBF-LB/P) with laser radiation in the near-infrared (NIR) region. By tuning PA12 and TPU powders with CuS and LaB6 nanoparticles, made by scalable high-power laser fragmentation and downstream-supporting, the absorption of PBF-NIR laser energy will be increased, which enables beam shaping options. Note that switching from the conventional CO2 (10600 nm) to a NIR laser source (808 nm) allows beam shaping devices to improve the temporal and spatial control of the energy input into the process zone. Our experimental setup will use a digital light processor (DLP) for a simultaneous and adjustable laser energy input over an entire area to control the heating and cooling conditions in the process chamber. During the process, microscopic changes in the material are expected to affect final part properties macroscopically. The experiments will be substantiated by a simulation model that takes into account the heat dissipation and distribution into the nano-additivated material after its development and validation. Therefore, our project includes investigating both the material-related and the process-related influencing factors to pave the way for improved, predictable, and controllable PBF-LB/P processing of tunable polymer composites by adaptive, simultaneous NIR exposure strategies.