Method of laser-based additive manufacturing with pulse scan patterns for magnesium and its alloys
AssigneeOsseolabs Company Limited
InventorsPatcharapit Promoppatum, Montian Sukpasert, Vikram Ahuja, Ola Harrysson
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Abstract
This invention introduces an advanced pulse scanning technique for Selective Laser Melting (SLM) of magnesium, addressing critical manufacturing challenges. The method employs iterative optimization to regulate heat input through precise pulse patterns, preventing overheating and material defects. By alternating between powered and unpowered laser phases, the technique reduces material evaporation, minimizes internal stresses, and enhances microstructural uniformity. This approach enables more stable and efficient fabrication of magnesium components for aerospace, biomedical, and industrial applications.
Claims8
A method of additive manufacturing a magnesium or magnesium alloy object using a Selective Laser Melting (SLM) system, the method comprising:
- providing initial parameters including laser power and scanning speed for a magnesium or magnesium alloy powder;
- generating an initial pulse scan pattern comprising alternating ON and OFF durations;
- and controlling a laser source of the SLM system to irradiate a powder bed of the magnesium or magnesium alloy powder according to a pulse scan pattern to physically fabricate the object, wherein the improvement comprises:
- executing a computational thermal simulation based on a physics-based heat transfer model by a computer processor to predict a maximum melt pool temperature based on the initial pulse scan pattern;
- and iteratively adjusting the ON and OFF durations of the pulse scan pattern by the computer processor until the predicted maximum melt pool temperature satisfies the condition:
- Tm<Max(T)<Tb, wherein Tm is the melting point and Tb is the boiling point of the magnesium or magnesium alloy, prior to controlling the laser source to irradiate the powder bed according to the adjusted pulse scan pattern.
An additive manufacturing system for fabricating a magnesium or magnesium alloy object, comprising:
- a build platform containing a magnesium or magnesium alloy powder bed;
- a laser source configured to emit a pulse-modulated laser beam;
- and a controller operatively coupled to the laser source, wherein the controller is programmed to execute a computational thermal simulation based on a physics-based heat transfer model to predict a maximum melt pool temperature, iteratively adjust ON and OFF durations of the pulse-modulated laser beam such that the predicted maximum melt pool temperature is maintained above the melting point (Tm) and below the boiling point (Tb) of the magnesium or magnesium alloy powder, and direct the laser source to fuse the powder based on the adjusted ON and OFF durations to physically fabricate the object.
Dependencies are inferred from the claim text.