Powder Laser Energy Deposition

Metal Technologies Powder Laser Energy Deposition

Powder Laser Energy Deposition

Additive Manufacturing based on established welding technology

Powder Laser Energy Deposition (ED), also known as Laser Metal Deposition (LMD) is a welding technology used for many years. Recently the technology is adopted as an Additive Manufacturing technology by system integrators and off-the-shelf system providers. In this section you learn about the background of Powder Laser ED.

Laser Metal Deposition application

What you will find in this section

Technology principle

How does Powder Laser Energy Deposition work?

Powder Laser ED, also sometimes referred to as Laser Metal Deposition (LMD), is a welding technology in which a laser forms a melt pool on a metallic parts’ surface. At the same time a powder feedstock is blown through a nozzle into the process zone, where it is preheated by the laser and then absorbed by the melt pool. After solidifying, raised welding beads remain. By repeating the process, the welding beads are built on top of each other and a three-dimensional structure is formed. Powder Laser Energy Deposition is a sub-group of the Direct Energy Deposition technologies. Typical for DED technologies is the high deposition rate of material, which is locally applied to form near net-shape blanks.

Pre- and post processing

High efforts for data preparation for DED technologies

Before the actual build process can start a relatively complex data preparation takes place which is very similar to data preparation for CNC machines.

When designing the part, the orientation and possible integration of the substrate has to be considered. Then, offsets between the deposition tracks are defined. Support structures are not necessary, since parts are directly deposited on a substrate. However, printing overhangs without tilting the build platform is only possible up to an angle of about 20° degrees. Thus, to manufacture any overhanging structures, axes movement has to be considered in order to manipulate the part orientation with reference to the processing unit.

The toolpath and the subsequent processing are dependent on the type of geometry, that needs to be created. The processing strategy and its toolpath are programmed individually for each type of geometry. For preparation of this task, the part is segmented into individual sections using a CAD software. So far, only semi-automatic CAM solutions for assigning a processing strategy and toolpath to a segment exist (for example from SIEMENS).

After the build job, parts are generally post-processed by a thermal treatment and machining. A detaching of the part from the build platform does normally not take place as the build platform is part of the geometry. Since the Powder Laser Deposition technology includes a welding process with high temperature gradients, residual stresses occur. To avoid deformation during processing, the substrate requires strong clamping fixtures. The stresses are removed in a subsequent heat treatment. For increasing the surface quality of the part, machining of the surface takes place.

Development history

Long history in cladding applications

Powder Laser Energy Deposition is known as a coating and welding technology for several decades. The process is well-established and common throughout industries for cladding of metallic surfaces and minor repairs. The technology has been field of interest for research institutions and other R&D activities for decades. Additional to process development and material qualification, specialized working heads with multiple nozzle shapes have been developed for specific applications.
First industrial additive applications have been the repair of turbine blades. The worn and damaged tips of the blade are cut off and Powder Laser Deposition is used to re-apply the material. Recently the technology was adapted as an Additive Manufacturing technology by system integrators and off-the-shelf system providers more widely. Besides repair and part individualization the technology is more and more used for the production of large near net-shape blanks. Today, the digital data preparation represents the major hurdle for a faster adoption of the technology. The pre-processing steps require a lot of knowledge, manual input and programming. Also, extensive testing of build strategies and cooling times are necessary for each new part geometry.

Supply chain

Integrators and solution providers set heterogenous supply chain

Customers interested in Powder Laser Energy Deposition have two possibilities for purchasing the machine technology. On the one hand system integrators exist, that use working heads that are integrated into handling and machine technology specifically designed for one application. Along with complete manufacturing systems, DM3D offers this kind of system integration. On the other hand, there are suppliers, that provide turn-key solutions that include machine technology, processing settings as well as feedstock material. Examples of such suppliers are BEAM, DMG MORI and TRUMPF.

Customer-specific integrated solutions come into play in case of applications with high lot sizes that are produced over a longer period. Integration is more cost-efficient but connected to losses in flexibility. Within Additive Manufacturing, flexibility and individualized parts are important selling points. Therefore, system providers with flexible solutions are expected to find a market.

Advantages and disadvantages

Powder Laser Energy Deposition technology based on machining and coating history

High build rate

The build rate in cm³/h is 2 – 3 times higher compared to L-PBF.

Flexible machine technology

Multiple suppliers of working heads and/or completely integrated turn-key systems offer solutions for a wide range of different applications.

Highest resolution for DED technologies

Specialized working heads allow for “micro” applications with resolutions below 1 mm.

High effort for data preparation

CNC based tool path programming is time consuming and requires experience.

Cooling time decreases productivity

Depending on part geometry cooling phases to prevent overheating can make up to 50% of the manufacturing time.

Process video

The technology in action

Below you can see a video of the Powder Laser ED process from Italian machine manufacturer BeAM. They use powder as a feedstock and a laser to melt the powder. 

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Sinter-based AM technologies and process chain

Sinter-based AM - a technology overview

Many different printing technologies - one sintering process

The sinter-based AM (SBAM) technologies have, as the name suggests, the sintering process in common. In this process, the printed green part is consolidated into a dense part and receives its final properties. The green part can be printed in advance using different technologies.They all have in common that metal powder is bound to the desired shape by a binder. The best-known printing technologies include Binder Jetting and Filament Material Extrusion.

In this section, you learn everything about the sinter-based AM  process chain and get an overview of the different printing technologies.

Goal and structure of this course

This course is aimed at engineers, designers and other professionals that are working closely with sinter-based AM technologies. The goal is to cover the most important aspects that will enable engineers and designers to fully grasp the capabilities and technical limitations of the printing technologies and the sintering process to succeed in technology selection and part design. Besides going through the course from the beginning until the end, this course can also act as a constant source of knowledge while working on AM projects. 

The course is structured into the following sections.

This section will start with an overview of the sinter-based AM process chain and its printing technologies, followed by a technology deep dive into the most important aspects of the BJT technology, followed by a closer look at the debinding and sintering step also including sintering simulation .

The second section will provide an overview of the different materials that are available as well as part characteristics that can be achieved with the BJT process and typical methods for quality assurance. Finally, several common defects in the BJT process are presented. 

The last section will act as a guideline for designers. Besides generally describing the process when designing for Additive Manufacturing, actionable restrictions and guidelines for the BJT process are provided. The final section will present several design examples from different industries. 

What you will find in this section

Sinter-based AM process chain

From digital model to finished part

Data preparation

Simulation to compensate the deformation during the sintering step, nesting of parts and definition of printing parameters

Printing

Through various printing processes, different feedstocks such as metal powders, filaments, pellets or dispersions are processed into green parts

Unpacking

Unpacking of fragile green parts needs to be done carefully and is typically a manual process.

Debinding

Debinding describes the process of removing the binder which results in a brown part

Sintering

To reach the structural integrity of a metal part, a sinter process is required. The powder particles fuse together to a coherent, solid structure via a mass transport that occurs at the atomic scale driven via diffusional forces.

The brown part shrinks ~13-21 % in each direction.

The process chain of sinter-based technologies differs from other AM Technologies. Especially the post-printing processes (debinding and sintering) are crucial to achieve the intended mechanical properties.

Technology principle

How does Binder Jetting work?

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting

Afterwards the build platform moves downward by the amount of one layer thickness and a new layer of powder is applied. Again, the liquid binder is deposited and hardened in the required regions of the next layer to form the green body. This process is repeated until the complete part is printed. After the complete printing process is finished the parts have to be removed from the “powder cake” meaning the surrounding loose but densified powder. To improve the removal of the excess powder from the green body often brushes or a blasting gun with air pressure are used.

To create a dense metal part the 3D printed green body has to be post-processed in a debinding and sintering process. Similar to the metal injection molding process BJT parts are placed in a high temperature furnace, where the binder is burnt out and the remaining metal particles are sintered together. The sintering results in densification of the 3D printed green body to a metal part with high densities of 97 % to 99,5%, dependent of the material.

Printing Technologies

Metal Binder Jetting

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting

Material Extrusion

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting

Mold Slurry Deposition

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting

Metal Selective Laser Sintering

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting