Shape Deviation of Surface Structures Produced by WaveShape (Structuring by Laser Remelting) on Ti6Al4V and a Method for Deviation Reduction

Micromachines, vol. 12, pp. 367

Abstract

Laser structuring by remelting (WaveShape) is a manufacturing process for metal surfaces in which structures are generated without material removal. The structuring principle is based on the controlled motion of the three-phase line in the area of the solidification front. The contour of the solidification front is imprinted into the remelting track during the continuous solidification process. Typically, harmonic surface structures in the form of sinusoidal oscillations are generated by means of WaveShape with virtually no material loss. However, a significant shape deviation is often observed over a wide range of process parameters. In this study, it was found that much of the shape deviation is concentrated at a spatial wavelength equal to half the spatial wavelength used for structuring. Therefore, an approach to reduce the shape deviations was specifically investigated by superimposing a compensation signal on the harmonic structuring signal. In this approach, a compensation signal with half the spatial wavelength was varied in phase and amplitude and superimposed on the structuring signal. Amplitude and phase shift of the compensation signal were further investigated for selected laser beam diameters and spatial wavelengths. This demonstrated that a shape deviation of harmonic surface structures on titanium alloy Ti6Al4V could be reduced by up to 91% by means of an adapted compensation signal.

Authors 5

1. Oleg Oreshkin corresponding

   National Research Nuclear University MEPhI

   Affiliation as printed

   Moscow Engineering Physics Institute, National Research Nuclear University MEPhI, Kashirskoe Shosse 31, 115409 Moscow, Russia

2. Daniil V. Panov

   Skolkovo Institute of Science and Technology

   Affiliation as printed

   Center for Design, Manufacturing & Materials, Skolkovo Institute of Science and Technology, Bolshoy Boulevard 30, bld. 1, 121205 Moscow, Russia

3. Laura Kreinest Aachen Chair for Digital Additive Production

   RWTH Aachen University

   Affiliation as printed

   Chair for Digital Additive Production, RWTH Aachen University, Campus-Boulevard 73, 52074 Aachen, Germany

4. André Temmler corresponding

   Fraunhofer Institute for Applied Optics and Precision Engineering

   Affiliation as printed

   Fraunhofer Institute for Applied Optics and Precision Engineering, Albert-Einstein-Straße 7, 07745 Jena, Germany

5. Alexander Platonov

   National Research Nuclear University MEPhI

   Affiliation as printed

   Moscow Engineering Physics Institute, National Research Nuclear University MEPhI, Kashirskoe Shosse 31, 115409 Moscow, Russia