Metal Additive Manufacturing Conference - MAMC 2023

A notable limitation in current commercial laser powder bed fusion (LPBF) systems emanates from the non-uniform thermal conditions caused by conventional laser beams. The utilization of Gaussian intensity patterns in existing setups gives rise to significant issues, including excessive overheating and material evaporation, stemming from the concentration of energy at the central beam point. Conversely, the beam peripheries experience low intensity and inadequate heat conduction, impeding the attainment of the required material melting point. In this study, we have developed a dynamic beam shaping technology based on a Liquid Crystal on Silicon (LCoS)-type spatial light modulator. This advancement addresses the existing limitations and enhances both the efficiency and quality of the LPBF process. The proposed technology exhibits promising potential to yield a significant upsurge in the productivity and part quality of the LPBF process. Here we present a breakthrough in enhancing the printability of Zr-based bulk metallic glass by utilizing proper beam shape to reduce the HAZ and chance for crystallization of BMGs during LPBF process.
Keywords: Laser Powder Bed fusion, Beam Shaping, Bulk Metallic Glasses