R. Bernhard
P. Neef
H. Wiche
V. Wesling
C. Hoff
J. Hermsdorf
S. Kaierle

Process development for additive multi-material components

Proc. Lasers in Manufacturing (LiM)
Type: Zeitschriftenaufsatz (non-reviewed)
Suppliers of laser systems face worldwide competition. In order to stay on the market and remain competitive, it is necessary to improve products and processes continually. Additive manufacturing of metals has emerged as a potential technology for companies to create highly integrated and individualized products. Building on this, the subsequent step is to integrate optomechanical and thermal properties into these structural parts. This is done by combining and encapsulating optical elements like quartz lenses or laser crystals with special nickel-iron alloys and thus creating multi-material components. Furthermore, matched thermal expansion coefficients of the used materials and integrated cooling solutions are supposed to reduce mechanical stress and improve optical properties of the assembly. The objective is to develop a lean single-stage process with minimal handling of the fragile laser components. First experiments using powder-based laser metal deposition with a 680 W diode laser show success in encapsulating and bonding different materials. Microsections were used to analyze the specimens regarding structural integrity and defects.