The trend for 3D printing parts for aerospace propulsion applications has pushed build envelopes of metal additive systems to be larger, which has in turn, necessitated more lasers for throughput and process performance. Larger parts benefit from these evolutions, however, multi-laser systems introduce new variables that could impact part quality, which is especially critical on turbo-machinery and other rotating and/or pressurized components. Optical system calibration and monitoring, as well as effective laser scheduling, become critically important in order to satisfy quality specifications. In this presentation, we look at the effect of optical system calibration and health between the lasers in a dual-laser system in terms of part outcomes, and what can be done to ensure and maintain sufficient alignment between the lasers. We also look at the effect of laser-to-laser interaction.
- Understand critical parameters for optical system health and statistical process control
- Understand Laser-to-laser calibration methods
- Determine the effect of overlay on mechanical properties of parts