Multi-Laser Diode Area Melting - The next generation in additive manufacturing of metallic alloys

Details

Laser powder bed fusion (LPBF) is an Additive Manufacturing (AM) technique that in recent years has seen a significant increase in industrial usage for the manufacture of high-value end-use components, creating geometrically efficient complex structures with low material wastage. However, the LPBF processing methodology has not evolved in over two decades, relying on galvo-scanning systems and high power fibre lasers to selectively melt thin layers of feedstock from a powder bed. This approach creates challenges in regard to LPBF system scalability, processing efficiency (due to poor laser absorption and wall-plug efficiency) and thermal process control that is associated with rapid melt-pool solidification, subsequently leading to the creation of components defects (e.g cracking, distortion).

 This PhD research will investigate a new multi-laser process invented at the University of Sheffield, known as Diode Area Melting (DAM) (see Fig 1a). The process uses multiple arrays of efficient low wavelength (450-808nm) highly focused diode lasers to melt pre-deposited feedstock from a powder bed. This approach offers improved system scalability and thermal control compared to state-of-the-art LPBF. The DAM system to be used during this research will integrate 147 lasers stacked in a unique 2D array enabling advanced in-situ thermal pre/post-heating (see Fig 1b). The project sits across the Departments of Mechanical and Electronic & Electrical Engineering, and therefore offers the opportunity to work across standard discipline boundaries and will support student skillset development over a broad range of specific interests. The research will focus on developing the system hardware and control (e.g control software to bridge gap between CAD and machine control, beam profiles), understanding multi-laser interactions (see Fig 1c) and their influence on microstructure and mechanical performance of components.

 This is a fantastic opportunity to develop new science and knowledge related to this unique system that has the potential to revolutionise the AM industry. 

Further Information

·        Candidates should have, or expect to obtain, a first-class or 2:1 degree in Engineering, Physics or Science related discipline.

·        Deadline 24^th Jan 2024

Please apply by using the following link and select University of Sheffield Research Scholarships University of Sheffield Research Scholarships | Postgraduate study | The University of Sheffield

Please state that you are applying for the above project.