Development of a Novel Industrial Metal Laser Melting Device and Its Performance Investigation

Yıl 2025, Cilt: 40 Sayı: 3, 1479 - 1494

Mehmet Alper Demiray , Bahri Şekerci , Mert Gürgen , Cengiz Kayacan , Cengiz Baykasoglu

https://doi.org/10.17341/gazimmfd.1424568

Öz

Additive manufacturing (AM) technologies began to be used all over the world in parallel to 4th Industrial Revolution. Selective Laser Melting Method (SLM) is one of the most preferred AM methods. Developing these types of devices become importance day after day through advantages such as having the minimum cost of waste material by using powder raw material, manufacturability of complex shaped and lattice structured parts, adaptability for topology optimization process. In this study, a unique selective laser melting device which has a unique preheated-double side functioned recoater was designed and manufactured with all its mechanic and electronic/electro-optic equipment. It has also double laser scanning function and positioning mechanism to tune finely focal length of the scanner heads. In view of SLM devices, focal length directly effects the beam diameter on the powder surface which is determined by used laser-optic equipment that can be selected based on mathematical expressions (theoretical beam diameter) and existing beam during manufacturing (experimental beam diameter) For investigation and testing of the efficiency of developed device, single laser track lines with different laser powers was manufactured and investigated. Test results showed that, experimental beam diameter was found as consistent with the theoretical one between 100 W and 200 W. At other power levels, track widths were found as increasing proportional to increasing power in parallel to literature. On the other hand, both melt pool depths and widths were obtained effective at 60 ve 90 J/mm^2 among 3 different experienced energy density.

Anahtar Kelimeler

Selective laser melting device, preheating recoater, laser track, laser optic

Proje Numarası

217M499, FDK-7329

Endüstriyel bir metal lazer ergitme cihazının özgün olarak geliştirilmesi ve performansının araştırılması

Öz

Eklemeli imalat (Eİ) teknolojileri dördüncü endüstri devrimine paralel olarak tüm dünyada yaygın şekilde kullanılmaya başlamıştır. Seçmeli lazer ergitme yöntemi (SLE) de parça imalatında birçok alanda en çok tercih edilen Eİ yöntemlerindendir. Kullanılan toz hammadde bakımından az atık malzeme, karmaşık geometrili parçaların nete yakın ölçülerde imal edilebilirliği, topoloji eniyileme süreçlerine uyumluluk gibi avantajlarından dolayı SLE teknolojilerin etkin şekilde uygulanmasına yönelik yeni cihaz geliştirilmesi çalışmaları her geçen gün daha da önem kazanmaktadır. Bu çalışmada özgün ön ısıtma ve çift taraflı serme özelliğine sahip toz serici barındıran bir seçmeli lazer ergitme cihazı geliştirilmiş ve tüm mekanik, elektronik ve elektro-optik ekipmanları ile birlikte imal edilmiştir. Bu cihaz bunun yanında iki lazer güç kaynağı ve tarayıcı kafaların odak uzunluğunun ayarlanabilmesini sağlayan bir konumlandırma mekanizması da barındırmaktadır. SLE cihazları için odak uzunluğu, matematiksel ifadelere göre seçilen lazer optik ekipmanların toz yatağı üzerinde oluşturması istenen lazer ışın çapını (teorik ışın çapı) ve gerçek bir imalat sırasında oluşan ışın çapını (deneysel ışın çapı) doğrudan etkilemektedir. Bu çalışma kapsamında cihazın kabiliyet ve performansının incelenip test edilmesi noktasında farklı güç değerlerinde lazer çizgileri oluşturulup detaylı şekilde incelenmiştir. Yapılan testler sonucunda 100 W ile 200 W aralığı için teorik ve deneysel ışın çapı en benzer olarak elde edilmiş ve diğer parametrelerde de artan güce oranla artan genişlik ve derinlikler literatür verileriyle uyumlu gözlemlenmiştir. Bununla birlikte denenen 3 farklı enerji yoğunluğu arasında 60 ve 90 J/mm^2 değerlerinde hem genişlikler hem de ergiyik havuzu derinlik değerleri etkin imalat yapılabilecek şekilde bulunmuştur.

Anahtar Kelimeler

Seçmeli lazer ergitme cihazı, ön ısıtmalı serici, lazer çizgisi, lazer optik

Destekleyen Kurum

TÜBİTAK, SDÜBAP

Proje Numarası

217M499, FDK-7329

Teşekkür

Yazarlar 217M799 No’lu Proje ile bu çalışmanın yapılmasına destek verdiği için TUBİTAK’a ve FDK-7329 no’lu BAP projesi ile destek verdiği için SDÜ BAP Koordinatörlüğüne teşekkürlerini sunar.

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