Rapid fabrication of ion optics by selective laser melting

Sangregorio, Miguel; Wang, Ningfei; Xie, Kan; Zhang, Zun; Wang, Xiaojun

doi:10.1108/rpj-05-2017-0085

Cited by 5 publications

(2 citation statements)

References 19 publications

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“…In the case of trepan cutting, the focus is moved along a helix trajectory into the hole. Flexibility in terms of the shape and dimensions of the holes and high accuracy, especially for hole edges, are the advantages of laser drilling (Dubey and Yadava, 2008; Sangregorio et al , 2019). LB-SM is particularly useful for cutting brittle and hard materials or any materials with unfavorable thermal properties, such as a material with low thermal diffusivity or conductivity (Davim, 2013).…”

Section: Laser Beam Manufacturing Principlesmentioning

confidence: 99%

Laser subtractive and laser powder bed fusion of metals: review of process and production features

Khorasani¹,

Gibson

Ghasemi³

et al. 2023

RPJ

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Purpose The purpose of this study is, to compare laser-based additive manufacturing and subtractive methods. Laser-based manufacturing is a widely used, noncontact, advanced manufacturing technique, which can be applied to a very wide range of materials, with particular emphasis on metals. In this paper, the governing principles of both laser-based subtractive of metals (LB-SM) and laser-based powder bed fusion (LB-PBF) of metallic materials are discussed and evaluated in terms of performance and capabilities. Using the principles of both laser-based methods, some new potential hybrid additive manufacturing options are discussed. Design methodology approach Production characteristics, such as surface quality, dimensional accuracy, material range, mechanical properties and applications, are reviewed and discussed. The process parameters for both LB-PBF and LB-SM were identified, and different factors that caused defects in both processes are explored. Advantages, disadvantages and limitations are explained and analyzed to shed light on the process selection for both additive and subtractive processes. Findings The performance of subtractive and additive processes is highly related to the material properties, such as diffusivity, reflectivity, thermal conductivity as well as laser parameters. LB-PBF has more influential factors affecting the quality of produced parts and is a more complex process. Both LB-SM and LB-PBF are flexible manufacturing methods that can be applied to a wide range of materials; however, they both suffer from low energy efficiency and production rate. These may be useful when producing highly innovative parts detailed, hollow products, such as medical implants. Originality value This paper reviews the literature for both LB-PBF and LB-SM; nevertheless, the main contributions of this paper are twofold. To the best of the authors’ knowledge, this paper is one of the first to discuss the effect of the production process (both additive and subtractive) on the quality of the produced components. Also, some options for the hybrid capability of both LB-PBF and LB-SM are suggested to produce complex components with the desired macro- and microscale features.

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Section: Laser Beam Manufacturing Principlesmentioning

confidence: 99%

Laser subtractive and laser powder bed fusion of metals: review of process and production features

Khorasani¹,

Gibson

Ghasemi³

et al. 2023

RPJ

View full text Add to dashboard Cite

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“…The blue line shows a quadratic fitting of the experimental data. The SLM machine proved to be able to guarantee tolerances under 20 µm, enough for typical aperture positioning [26].…”

Section: Proof Of Concept Of Titanium Amiomentioning

confidence: 99%

3D Printing of Ion Optics for Electric Propulsion

et al. 2019

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Additive manufacturing is rapidly opening its way into many areas of the aerospace industry, where different 3D printing technologies are finding niche applications in which they do not only simplify the process and allow shorter lead times, but also the particularities of these new fabrication methods yield new material properties that enhance the component and can lead to higher performance and longer service life of an aerospace system. Although rapid manufacturing processes are being tested for in-space manufacturing and are commonly used to fabricate UAV parts and some spacecraft subsystems with 3D printed components have been tested in space, little research has been conducted on the potential application of these techniques to electric thrusters. This paper presents the study conducted on the application of selective laser melting, a powder bed fusion technology, to the fabrication of ion engine grids and the challenges faced during the process. The first proof of concept and its optimization are described. Later, the development of the selective laser melting process for molybdenum, the study of the 3D printed materials' properties, their direct application to ion extraction systems, and the tests of additively-manufactured ion optics are described. It was found that 3D printed grids can be accurately fabricated with titanium and molybdenum, that they perform similar to conventional optics in short tests, that the selective laser melting process allows certain control of the coefficient of thermal expansion of the output and that this fabrication method allows the reproduction of sputtering erosion patterns. Future research in this direction will cover sputtering tests of selectively-laser-melted samples and the additive manufacturing of carbon-carbon grids.

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Review on volumetric energy density: influence on morphology and mechanical properties of Ti6Al4V manufactured via laser powder bed fusion

et al. 2022

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Various laser powder bed fusion (LPBF) process parameters must be considered as they can independently affect the properties of end-product. However, many studies simply examine one or two LPBF process parameters. Laser power, scan speed, scan spacing, and layer height are the four primary LPBF process parameters that contribute to volumetric energy density (VED) used in LPBF. VED is often used as an optimization metric for LPBF process parameters, because it takes all four major parameters into consideration. Thus, this paper focuses on the effect of VED on the morphology and properties of part, and also discusses on the interrelationship between all four parameters. Common range used for each parameter is 70–400 W for laser power, 70–1800 mm/s for scan speed, 50–140 µm for scan spacing, and 20–50 µm for layer height. It can be seen as the VED increased, the microstructure of as-built titanium alloy Ti6Al4V components exhibited smaller α’ martensite size and larger columnar β grain. High VED can also reduce porosity and defect formation, which will help in increasing part density. The lowest surface roughness reported for LPBF Ti6Al4V is 4.91 µm. Meanwhile, the maximum microhardness obtained is 443 HV and the highest tensile strength achieved is 1400 MPa. The VED used for studies that obtained these results are in the range of 55–65 J/mm3. Thus, it can be concluded that the most suitable VED for LPBF printing of Ti6Al4V is around 55–65 J/mm3.

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Rapid fabrication of ion optics by selective laser melting

Cited by 5 publications

References 19 publications

Laser subtractive and laser powder bed fusion of metals: review of process and production features

Laser subtractive and laser powder bed fusion of metals: review of process and production features

3D Printing of Ion Optics for Electric Propulsion

Review on volumetric energy density: influence on morphology and mechanical properties of Ti6Al4V manufactured via laser powder bed fusion

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