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Real-time Spectrographic analysis of melt pool composition for the generation of accurate functionally graded materials

Real-time Spectrographic analysis of melt pool composition for the generation of accurate functionally graded materials

Objective

Direct Laser Deposition (DLD) allows smart components to be built directly under CAD control. It has great potential for next generation manufacturing. This includes Functionally Graded Materials (FGMs) in which composition across an interface is gradually altered, as in a biological system.

The aim of this project is to investigate the possibility of real-time spectrographic analysis of the melt pool composition for the generation of accurate functionally graded materials. The proposed project will develop a process monitoring system for DLD applications.

This project is divided into 6 major objectives:
- Familiarization with laser equipment and different sensor systems during DLD process
- Identifying different materials via spectral analysis
- Incorporating analysis system into the laser deposition process
- Testing for multiple component materials (alloys)
- Experimental investigation for functional graded materials
- Optimization of the DLD system.

During processing the size/shape of the molten pool will vary, resulting in different levels of radiation. Any significant changes in the radiation intensity level may indicate potential failures of the process parameters. Thus, incorporating a high-resolution spectrometer into the DLD process would give significant information about the composition and accuracy.

The deposition of FGM is a dynamic process and therefore requires a real-time, accurate method of material composition analysis. Current methods concentrate on stages either before or after the deposition process. The proposed method is intended to allow dynamic alterations of process parameters to ensure the desired material compositions are maintained.

It is to be hoped that the process, when perfected, would also allow the real-time sensing of compositional irregularities such as Precipitate Free Zones (PFZs) or intermetallics. Review of the current state-of the art in the research field has failed to show any similar research efforts.

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Coordinator

FRAUNHOFER-GESELLSCHAFT ZUR FÖRDERUNG DER ANGEWANDTEN FORSCHUNG E. V.

Address

Hansastrasse 27 C
MÜNchen

Germany

Administrative Contact

Eckhard BEYER (Prof.)

Participants (1)

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FRAUNHOFER USA, INC.

United States

Project information

Grant agreement ID: 21513

  • Start date

    1 September 2006

  • End date

    31 August 2009

Funded under:

FP6-MOBILITY

Coordinated by:

FRAUNHOFER-GESELLSCHAFT ZUR FÖRDERUNG DER ANGEWANDTEN FORSCHUNG E. V.

Germany