30th of January 2017 Next Generation Manufacturing ... of January 2017 Next Generation Manufacturing: Industry 4.0 and Digital Photonic Production ... [email protected]

© Fraunhofer ILT

30th of January 2017

Next Generation Manufacturing:Industry 4.0 and Digital Photonic Production

Fraunhofer-Institut für Lasertechnik ILTSteinbachstraße 1552074 Aachen

Prof. Dr. Reinhart [email protected]

© Fraunhofer ILT

Digital Photonic Production and its impact on Industry 4.0

Example 1: Ultrafast Processing and Ablation

Example 2: Laser Metal Deposition LMD

Example 3: Selective Laser Melting SLM

Example 4: New Production chain for Precision Optics

Contents

© Fraunhofer ILT

1st Industrial

Revolution

1st Industrial RevolutionIntroduction of mechanical

production facilities powered by

water and steam

2nd Industrial RevolutionIntroduction of mass production

based on the division of labour

powered by electrical energy

3rd Industrial RevolutionIntroduction of electronics and

IT for the further automation

of production

4th Industrial RevolutionBased on cyber-physical

production systems

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Industry 4.0 and its Impact

Technology

networked

within a

machine or

product

multicore

technology,

ubiquitious,

with unlimited

connectivity

Internet of Things

Smart Factory

Improved

efficiency in

tooling and

maintenance

"Lot size 1"

CPS-equipped

products under

assembly steer

the production

process, making

production

extremely flexible

and efficient

Digital Business

Manual or semi-

automatic control of

production and business

"Digital Company"

Automated digital

interaction between

machinery, business

process management,

external partners

(suppliers, logistics,

distributors), and

customers

Fully integrated digital business

To

da

yTo

mo

rro

w

Workforce

Skilled labour,

adaptive

organisation

"Expert All-

Rounder"

Multi-competent,

flexible workforce,

interacting on all

levels of business

and with partners

Cyber-Physical

Systems

Embedded

Systems

© Fraunhofer ILT

Digital Photonic Production – A new Industrial Revolution?

Product complexity

ConventionalProduction

Lot size

Cost Cost


© Fraunhofer ILT


Product complexity


Lot size


Individualisation for free Individualisation for free

Cost Cost

laser based manufacturinglaser based manufacturing

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Product complexityLot size

Individualisation for free Individualisation for free

Cost Cost

DigitalPhotonic Production

DigitalPhotonic Production

Laserstrahl

umgeschmolzene

Schicht

Schmelzbad

Bewegungsrichtung

des Laserstrahls

Pulverschicht

SLM 1-3 cm3 / min LMD 10-30 cm3 / min Ablation 0,2-0,5 cm3 / min

laser based manufacturinglaser based manufacturing




© Fraunhofer ILT

Impact of Digital Photonic Production to Industry 4.0 –The Aachen perspective

physical

cyber

hardwaresoftware

4. Industrielle Revolution

Kollaborations-

produktivität- Mensch/Mensch

- Mensch/Maschine

- Maschine/Maschine

IT-Software: truth

PLM-Systems

ERP-Systems

Physical Systems:

automation

Cognitive Systems

Social Behavior:

cooperation

Business

Communities

Social

Communities

IT-Hardware: speed

Saving to the

cloud

High Speed

Computing

Sensor technology

© SICK AG

4th industrial revolution

Collaboration-

productivity- human/human

- human/machine

- machine/machine

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Digital Photonic Production –“Directly from CAD to Product”

Using light as a tool means …

highest power density

highest speed

shortest interaction (precision)

mass-less, force-less, no tools

best controllability (CAD to product)

© Fraunhofer ILT

Example 1: Ultrafast Processing

Why fs-pulses?

© Fraunhofer ILT

Time Scales of Thermal Processes – Melt Film Thickness

Material depth z

Melt temperature

Vaporization temperature

Environmeltal temperature

Tem

pera

ture

T

Melt film thickness

Heat penetration depth T0

TS

TV

Steel

Pulse duration t [s]

Aluminium

Heat

pen

etr

atio

nd

ep

thd

th

[m]

10-15

10-10

10-7

10-4

10-12 10-9 10-6 10-3

tth d 410-8

10-9

10-5

10-6

10-3

m/s61012

m/s61097

t

zierfct

ITtzT abs

44, 0

© Fraunhofer ILT

Steel Ceramics Polymers

BasicsMaterials

Ceramic-Substrates for printed circuit boards

Ceramic micro components

PCD- andSapphire-Tools

Injection molding tools

Forming tools

Tribological structures

Medical technology

Micro fluidics

Micro optics

© Fraunhofer ILT

Innoslab Platform – History

1994 1996 1998 2000 2002 2004 2006 2008 2010 2012

Patentpartiallypumpedslab laser

Patentslabamplifier

FoundationofEdgeWave2001

FoundationofAMPHOS2010

First demon-stration

Nd:Innoslabamplifier

50 W

Nd:InnoslabCWOscillator

1 kW

ATLAS LIDAR source

100 mJ

Nd:Innoslabamplifier

400 W ns, ps

Yb:Innoslabamplifier

kW fs

© Fraunhofer ILT

Multipass ThinDisk Amplifier – record fs power

Seeder

Innoslab MOPA

630 W Power Amplifier

ThinDisk Multiplass Amplifier

CW pumped

18 reflections on disk

Demonstrated Results

1.5 kW output

37.5 µJ

711 fs

M² = 1.5 x 2.0

© Fraunhofer ILT

high reprate / low pulse energy

System strategies for productivity increase

Increase of average laser power byhigh pulse repetition rate

thigh pulse energy / low reprate

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Applications of ultrafast machining-high precis ion structuring of emboss ing and injection molding tools

• Clear replication of CAD-Data• No melt and debris• Surface roughness < 0.5 µm

3D-Structuring of emboss ing rolls

Material: Copper, chrome-platedRoll: 250 mm diameter, 1 m lengthRoller rotation speed: 1400 U/min Line scan distance : 2 µm-> surface speed: 15 m/s-> spot distance @ 2 MHz: 7,5 µmLaser power: 100 WSpot size: 10 µmRepetion rate: 3 MHz

5 mm

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Cutting with Ultra-Short-Pulse Lasers

exit side

HAZ ≈ 70 µm

entry side

HAZ ≈ 250 µm

P = 400W , F = 1 J/cm², frep= 6.3 MHz

Repetitive ablation of 300 µm kerf

Cutting speed 0.3 m/min

HAZ <25 µm in low power range <100 W

CFRP processing with EdgeWave ps laser at 30 W

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Increase of average laser power byhigh pulse repetition rate

thigh pulse energy / low reprate

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Increasing Producivity - Influence of Pulse Energy

Nano structuring withRipple-Formationat low pulse energies

Micro structuringWith production of cone like protusions at high pulse energies

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Large Area structuring with laser radiation

Micro structuring of wind rotors- Anti icing- Anti sticking of insects- Structur size < 10 µm

Micro- and nano structuresto generate functionalsurfaces

Quelle:fos4x

Quelle:phereclus

© Fraunhofer ILT

t



Increase of Pulse energy and beam splitting

high pulse energy / low reprate

t

t

t

t

Multiple beams withreduced fluence

© Fraunhofer ILT

MultiBeamScanner (MBS)Optical Principle

Laser process ing with a spot array instead of a s ingle spot

© Fraunhofer ILT

Video: Parallel laser processing using 196 beams

Multiscanner.mp4

Multiscanner.mp4

© Fraunhofer ILT

Laser structuring of motor components

Aim: Reduction of friction and wear

Approach: Micro and nano structuring ofcylinder liners and piston rings

Use of high power ultra short pulsed lasers

Cylinder liner

Piston ring

© Fraunhofer ILT

Micro holes in airfoils for interface designing

- Hole diameter < 200 µm- Variable hole pattern/ drilling sequence- Shaped holes for improved gas flow

Drilling rate > 10.000 holes /sec

Different drilling techniques

Single Pulse

Percussion

Helical drilling

Quelle:Airbus

Large Area structuring with laser radiation

Reduction of fuel use: >10%

© Fraunhofer ILT

Programmable Multi Beam Hybrid Optics (Spacial Light Modulators)

Combination Scanner + Programmable Diffractive Optics(PDO)

20-40 single beams

Up to 10 µJ/beam

>10.000 holes / s

© Fraunhofer ILT

Change of beam profile „on the fly“

Switching time 20ms

300µm

Programmable Multi Beam Hybrid Optics

© Fraunhofer ILT

Example 2: LMD

© Fraunhofer ILT

LMD: Generation of Part directly from CAD Data

CAD Data“Slicing”

Part

Steel (316L)

Construction

time 20 min

© Fraunhofer ILT

Laser Metal Deposition LMD

Process

BLISK Blade additivelymanufactured by LMD

© Fraunhofer ILT

LMD – ALSI10MG.

RESULTS TENSILE TESTING.

Fig.: “Minimal” strength of cast and AM aluminum (tensile testing)[Casting: DIN EN 1706; LMD: Thiele; SLM: Buchbinder]

0

2

4

6

8

10

12

14

16

0

50

100

150

200

250

300

Fmin - pressurecasting

Fmin - die casting Fmin - sandcasting

Fmin - LMD Fmin - SLM

Elo

ng

ati

on

at

bre

ak

At

[%]

Yie

ldst

ren

gth

Rp

0,2

, t

en

sile

stre

ng

thR

m[M

Pa

]

yield strength tensile strength

elongation at break

© Fraunhofer ILT

Power Cladding with oscillating solidification front

Page 32

Objective: generation of small grains

cross section of cube – 4 layers

EBSD analysis

determination of working point via numerical modelling

oscillation frequency too small

oscillation frequency suitable

© Fraunhofer ILT

Laser Metal Deposition – SX on SX

three layers with overlapping tracks

cross section

Page 33

Microstructure with one dendrite growth direction

no stray grains

no cracks

730

µm

230 µm

growth direction of dendrites

eviation of crystal orientation on top of the deposit

EBSD analysis

© Fraunhofer ILT

UNCONVENTIONAL MATERIAL PAIRINGSMMCs on grey cast iron, 30/min, up 20x

Disc brakes

Diameter: Ø 50 mm Length: 1 m

Cross-section

APPLICATIONS

Results

1:1 wt.-% | WC : IN625

Dilution < 1 %

Single layer thickness approx. 60 µm Diameter: Ø 300 mm

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Example 3: Selective Laser Melting

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The AM Revolution

Basic Patent

2003

First Implant

...to SeriesProduction

...fromPrototyping

1996First Production

2008

Engine Block?

20??

2001

First Tool Insert

SLM as one of the key enablers of AM

Lowering ofbuild platform

Laser Melting ofpowder material

Deposition ofpowder layer

© Fraunhofer ILT

Example:TiAl6V4 – Static Mechanical Properties

0,0

5,0

10,0

15,0

20,0

25,0

30,0

0

200

400

600

800

1000

1200

SLM WB 1 SLM WB 2 SLM HIP Fräsen MIM Feinguss Schmieden

Bre

ak

ing

Elo

ng

ati

on

A5

[%]

Te

nsi

le S

tre

ng

th R

m[M

Pa

]

Zugfestigkeit

BruchdehnungStandards ASTM F136

Tensile Strength

Breaking Elongation

Milling Casting Forging

SLM parts with adapted heat treatment (WB) achieve same static mechanical properties as forged/milled parts

SLM- Part properties

© Fraunhofer ILT

Component design with lattice structures –Stiffness, strength, energy absorption

=𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑙𝑎𝑡𝑡𝑖𝑐𝑒 𝑠𝑡𝑟𝑢𝑐𝑡𝑢𝑟𝑒

𝐶𝑢𝑏𝑖𝑐 𝑒𝑛𝑣𝑒𝑙𝑜𝑝𝑒 𝑣𝑜𝑙𝑢𝑚𝑒

F2ccz-type latticestructure for tensiletests

Yield

strength

© Fraunhofer ILT

Integrative ProductionExample: Race car axle, 30% increase of stiffness

© Fraunhofer ILT

Biodegradable Scaffold (WE43) Topology Optimized Triple Clamp (AZ91)

1:4 Scale Model

Ø 98mm build plate

Research Activities: New MaterialsMagnesium Alloys

© Fraunhofer ILT

Pseudoplasticity (shape memory effect) or super elasticity adjustable by choice of process parameters

Smallest feature size:approx. 30µm

Surface roughness Sa:< 2µm

MechanicalDeformation

100µm

Heating

Heating

Heating

Research Activities: New MaterialsShape memory alloys (NiTiNol)

© Fraunhofer ILT

Research activities: DesignMonolithic Functional Parts

© Fraunhofer ILT

Machine Concepts

Cost per part

Lot size

Conventional manufacturing

Selective Laser Melting (SLM)

High Power SLM machine

New AM machine

No clear trend in machine technology development

Parallelization of SLM processes

Usage of multiple lasersources

Two scan field Multi beams

Increase of laser power

Laser power up to 1 kW

Increase of laser beam diameter

Skin-Core principle

New System apprach„SLM 2.0“

© Fraunhofer ILT

Productivity – High Power SLMPylon Bracket Application

“Skin-Core”

1 mm skin thickness

1 kW core processing

300 W skin processing

“Conventional”

300 W processing (same parameters as skin)

30% decrease in built-up time due to skin-core processing

© Fraunhofer ILT

x

y

New SLM machine concept at ILTMulti-Spot processing

Conventional SLM New Multispot concept

© Fraunhofer ILT

SLM machine concept IIILaboratory Set-up of the Multi-Spot SLM machine

Productivity up 20-50x

Main advantages as a matter of principle:

Use of diode lasers

Easy upscaling in productivity (higher number of laser spots)

Easy upscaling in build size (larger axes)

Local shielding gas flow, local process control unit

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Example 4: New Production chain for precision Optics

© Fraunhofer ILT

Research aim: manufacturing of glass optics with laser radiation, especially aspheres and freeform optics

Manufacturing time independent from surface geometry

Vision: Fully Laser-based Optics ManufacturingDigital Photonic Production for Photonic Devices

© Fraunhofer ILT

Process aim: Processing of the geometry in short time with moderate roughness

Process principle:

Ablation of glass material through heating above ablation temperature

cw or pulsed CO2-laser radiation

Preheating for lower thermal stresses

Main process parametersPL, Δys, vs, n

Results :High ablation rate 𝑽 ≥ 20 mm³/s(1200 mm³/min) with 1.2 kW CO2 laser

Geometry Manufacturing by High Speed Laser Ablation

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Geometry Manufacturing by High Speed Laser AblationSample 20x20x5 mm³

© Fraunhofer ILT

Laser Polishing of GlassProcedural Principle and Experimental Setup

CO2-laser, = 10.6 µm, PL,max = 1.5 kW

Beam path

Z-Axis

X-Axis

Scanner

Heating plate

Extraction system

Crossjet

Flowbox

Pyrometer(not visible)

bLine

PL

vs

vfeed

bfield

lLine

TPreheat

Reducing glass viscosity through heating Material flow due to surface tension

-> Polishing without material removal Quasi-Line focus through high scan

speed vs

Preheating for lower thermal stresses

© Fraunhofer ILT

Laser Polishing of GlassGrinded Spherical Lens, Fused Silica, 25 mm

© Fraunhofer ILT

Laser Polishing of GlassRoughness, Fused Silica

Conv. pol.(/20)

Laser Polishing

mic

ro

rou

gh

ness

wa

vin

ess

micro roughness waviness

RMS 50 x 70

µm²

Rq1 x 1 mm²

Wq16 x 16

mm²

PV20 x 20

mm²

Conv. pol. (/20)

0,39 nm 0,3 nm 2,5 nm 0,3 µm

Laserpolished

0,33 nm 1,0 nm 6,1 nm 5,2 µm

Processing time for laser polishing: 1 - 5 s/cm²

Not sufficient for imaging optics yet-> Laser form correction by ablation

© Fraunhofer ILT

Summary

Significant impact of DPP on Industry 4.0

Multi-Process realization of DPP

- Ultrafast Ablation

- LMD

- SLM

- Combined process chains:

e.g. Ultrafast Ablation and Polishing

Many industrial apps demonstrated

Perspective of 30x increased productivity in next 5-10 years

QUESTIONS?

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End of Presentation

30th of January 2017 Next Generation Manufacturing ... of January 2017 Next Generation Manufacturing: Industry 4.0 and Digital Photonic Production ... [email protected]

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