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There is tremendous benefit in developing and qualifying novel alloys specifically designed to take advantage of unique microstructures produced with additive manufacturing (AM) processes. The bottleneck in such a development is the speed and cost of developing optimum print parameters to produce defect-free parts—as well as understanding the nuanced details that impact material quality in the laser powder bed fusion (PBF) process. Current parameter development schemes involve characterizing hundreds of coupons over multiple builds and can be a slow and expensive process. Additionally, recent developments in on- and off-axis monitoring—fused with machine health and geometry data—creates a rich environment of information that is often not well matched with traditional characterization approaches alone.

In this study, Zeiss presents leveraging a novel automated solution to comprehensively evaluate the effect of print parameters and process signatures on AlSiMg components coupled with a range of on and off-axis monitoring, machine health and geometry data. The solution presented also addresses a key challenge in creating a harmonized environment for answering fundamental questions regarding the laser PBF process. In addition to creating this environment, the rapid parameter development process can also aid in increasing the speed and economy of additive manufacturing to make the process cost competitive to the traditional manufacturing process.

Presented by:

Zeiss: Seeing beyond logo
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Paul Brackman
Additive Manufacturing Manager, Zeiss Industrial Quality Solutions
Paul joined Zeiss in 2016 working in Zeiss' ever-growing X-ray applications field. In his roles at Zeiss, Paul has been responsible for customer education, solutions development and technical sales. In 2019, Paul took over as the additive manufacturing manager for Zeiss, heading the AM Characterization Center located inside Oak Ridge National Laboratory's Manufacturing Demonstration Facility. As the AM manager, Paul is responsible for applications and operations as it pertains to Zeiss additive manufacturing research and development.
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Fred Carter
Ph.D. Student, Northwestern University
Fred started his graduate work at Northwestern University in 2019. He has held previous roles in both academic and commercial research related to both directed energy deposition (DED) and laser PBF metal AM. In his graduate work at Northwestern, Fred focuses on the intersection of AM machine control and monitoring with an emphasis on understanding the impacts and phenomena related to process gas flow, geometry and programmable laser control.
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