Double-Pulse Laser Micro Sintering for Low-Porosity Densification
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Solution Overview
Problem
Conventional laser sintering processes face challenges in achieving high densification and low porosity in sintered materials without compromising process efficiency, which affects the mechanical properties of produced parts and features.
Innovation Solution
The double-pulse laser micro sintering (DP-LMS) process involves sending sintering laser pulses to induce particle coalition, followed by pressing laser pulses with distinct parameters such as duration, energy, and spatial profile, and a time delay between the two, to enhance densification and reduce porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser sintering is used to increase densification and reduce porosity, then mechanical properties improve, but process efficiency significantly decreases
Solution Approach 1:
The laser pulse is segmented into two distinct phases: a sintering pulse for particle coalition and a pressing pulse for densification. This segmentation allows each pulse to be optimized for its specific function, achieving high densification without requiring excessive total energy input that would reduce process efficiency
Solution Approach 2:
The process uses periodic dual-pulse laser irradiation with specific timing intervals between sintering and pressing pulses. This periodic action with optimized pulse duration and spacing enables repeated cycles of particle bonding and densification, achieving high manufacturing precision while maintaining productivity through efficient energy utilization
2Manufacturing precision
If laser pulse energy is increased to improve densification, then porosity reduces, but process efficiency decreases
Solution Approach 1:
The invention changes the temporal parameters of laser energy delivery by using dual-pulse sequences with specific duration ratios and time intervals. This parameter optimization allows achieving the same porosity reduction effect with lower total energy input compared to conventional single high-energy pulses, thus improving energy efficiency while maintaining manufacturing precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
DP-LMS effectively increases densification and reduces porosity in sintered materials, improving mechanical properties without significant efficiency reduction, as demonstrated by experimental studies showing more continuous and densified regions compared to conventional methods.
Implementation Method 1
laser irradiating the material surface with one or more laser pulse groups to induce coalition of at least some of the powder particles
Implementation Method 2
coalition of two or more particles occurs directly or indirectly due to (at least partially) laser irradiation
Implementation Method 3
pressing laser pulse(s) for improving densification and reducing porosity of sintered material
Data Source
AI summary
Processes and systems that include one or more laser beam sources configured to provide laser irradiation with one or more laser pulse groups to at least a portion of powder particles on a solid surface at one or multiple locations thereof. Sintering laser pulse(s) is provided to induce coalition of at least some of the powder particles into a more continuous medium, and pressing laser pulse(s) is provided to produce pressure pulse(s) on at least a portion of the powder particles and/or the more continuous medium. Laser pulse groups may include one or more of the sintering laser pulses followed by one or more of the pressing laser pulses with a time delay between a last of the sintering laser pulse(s) and a first of the pressing laser pulse(s).