Enhanced Scaling of Material Removal Rate with High Surface Quality Through Combined Laser Processes

Abstract

AbstractIn the field of ultrashort pulse laser processing, the effective utilization of average power provided by todays laser systems presents an almost unsolvable challenge. This study aims to address this challenge in the context of laser volume ablation. We propose a solution for utilization of high average power while producing a high-quality finish, even when starting from arbitrary surfaces. The approach combines closed loop laser volume ablation, laser cleaning and laser polishing in a subsequent process strategy. The closed loop approach enables ablative laser processes to be used to produce precise target geometries and surfaces, even if the initial geometry of the component is very different from the target geometry. One application example is the post-processing of components manufactured using additive processes such as laser powder bed fusion. Therefore, we demonstrate automated removal of support structures and finishing of a sample made of AlSi10Mg material by laser powder bed fusion. The combination of laser ablation and laser polishing made it possible to significantly increase the productivity of the post-processing and achieving a surface roughness of Ra = 0.3 µm.