Energy Consumption and Saving Analysis for Laser Engineered Net Shaping of Metal Powders

Abstract

Abstract:With the increasing awareness of environmental protection and sustainable manufacturing, the environmental impact of laser additive manufacturing (LAM) technology has been attracting more and more attention. Aiming to quantitatively analyze the energy consumption and extract possible ways to save energy during the LAM process, this investigation studies the effects of input variables including laser power, scanning speed, and powder feed rate on the overall energy consumption during the laser deposition processes. Considering microhardness as a standard quality, the energy consumption of unit deposition volume (ECUDV, in J/mm 3 ) is proposed as a measure for the average applied energy of the fabricated metal part. The potential energy-saving benefits of the ultrasonic vibration-assisted laser engineering net shaping (LENS) process are also examined in this paper. The experimental results suggest that the theoretical and actual values of the energy consumption present different trends along with the same input variables. It is possible to reduce the energy consumption and, at the same time, maintain a good part quality and the optimal combination of the parameters referring to Inconel 718 as a material is laser power of 300 W, scanning speed of 8.47 mm/s and powder feed rate of 4 rpm. When the geometry shaping and microhardness are selected as evaluating criterions, American Iron and Steel Institute (AISI) 4140 powder will cause the largest energy consumption per unit volume. The ultrasonic vibration-assisted LENS process cannot only improve the clad quality, but can also decrease the energy consumption to a considerable extent.

A fundamental investigation on ultrasonic vibration-assisted laser engineered net shaping of stainless steel

“…Table 1. According to the values in Table 1, the theoretical energy density ɛ associated with the processes could be calculated by [43,44] h v…”

Investigation of Energy Requirements and Environmental Performance for Additive Manufacturing Processes

“…Except for the research on the energy consumption of AM processes, the benefits of AM over SM regarding the energy saving and environmental problems reduction also have been well-documented in previous literature [11][12][13]. It was reported that AM process could simplify or shorten the energy-intensive processes-such as casting, forging, rough machining, etc.-during the SM; therefore, it will generate less environmental impacts [14]. Comparing the energy demand for AM and SM in manufacturing polymer products, Kreiger et al indicated that AM could reduce the energy consumption by 41 to 64% due to the direct fabrication [15].…”

A Model of Ultra-Short Pulsed Laser Ablation of Metal with Considering Plasma Shielding and Non-Fourier Effect

“…Ultra-short pulsed laser ablation has received significant attention recently due to their better control, high power density, low energy dissipation, smaller heat-affected area, minimal collateral material damage, lower ablation thresholds, and excellent mechanical properties [1,2]. Therefore, Ultra-short pulsed laser ablation is being used in a variety of applications such as nanoparticle manufacturing [3,4], micromachining [5][6][7], surface modification [8], laser ablation propulsion [9], laser-induced breakdown spectroscopy [10], laser welding [11], among many others. During the ultra-short pulsed laser ablation process, the interaction between the laser beam and the target material will result in the ablation of the target and consequently the formation of a crater on the target surface [12].…”