LASER TECHNOLOGY live...9 Additive Manufacturing Laser-Powder Bed Fusion of Biodegradable Materials...

LASER TECHNOLOGY L IVE – AKL’16

AKL’18 – THURSDAY, MAY 3, 2018

TIME: 16.30 h - 19.30 h

LOCATION: AT FRAUNHOFER ILT

AND RESEARCH CAMPUS DPP

WWW.LASERCONGRESS.ORG

liveLASER TECHNOLOGY

Booth Plans Presentation Overview 1

Fraunhofer ILT – Short Profile 3Chamber of Industry & Commerce IHK Aachen 3Arbeitskreis Lasertechnik AKL e.V. 4 European Laser Institute ELI e.V 4

Presentations at Fraunhofer ILT 5 Presentations at Research Campus DPP 44 Publishing Notes 56Notes 57

CONTENT GROUND FLOOR

Additive Manufacturing

Generative Methods

Surface Treatment

Cutting

Central Information | Special Exhibit

Joining

Drilling

Micro Technology

Modeling & Simulation

System Technology

EUV & Plasma Technology

Laser and Laser Optics

Life Science

Laser Components

Solid State & Diode Lasers

1ST FLOOR

2ND FLOOR

BOOTH PLANResearch Campus DPP

BOOTH PLANGROUND FLOOR

BASEMENT

Additive Manufacturing

Generative Methods

Surface Treatment

Cutting

Central Information | Special Exhibit

Joining

Drilling

Micro Technology

Modeling & Simulation

System Technology

EUV & Plasma Technology

Laser and Laser Optics

Life Science

Fraunhofer ILT

OVERVIEWPRESENTATIONS


Page Topic Short Description Location Booth3 Central Information Fraunhofer Institute for Laser Technology ILT Entrance 13 Central Information Chamber of Industry and Commerce Aachen (IHK Aachen) Entrance 2a4 Central Information AKL e.V. - Aix Laser People Entrance 2b4 Central Information ELI - European Laser Institute Entrance 2c52 Central Information Digital Photonic Production Research Campus DPP – DPP Atrium 52a Jointly Shaping the Future5 Special Exhibit Heinrich Hertz Satellite Entrance 4a6 Special Exhibit The German-French Climate Mission MERLIN Entrance 4b6 Special Exhibit MERLIN Laser Source 3D-Model Entrance 4c47 Special Exhibit BMW i8 Roadster Marquee in Front 46 Research Campus DPP7 Additive Manufacturing Inner Processing Optics and Powder Feed Nozzles E100.C10 58 Additive Manufacturing Automatable Support Removal and Surface Smoothing Approach E100.C12.2 7a for L-PBF-manufactured Parts Made of Aluminum Alloys 9 Additive Manufacturing Laser-Powder Bed Fusion of Biodegradable Materials E100.C12 7b9 Additive Manufacturing Sensor Integration E100.C12.2 7c10 Additive Manufacturing LMI – Laser Melting Innovations E100.C13 8a10 Additive Manufacturing Scalable Machine Concept for Laser-Powder Bed Fusion E100.C13 8b11 Additive Manufacturing Powder Bed Fusion with Diode Laser E100.C13 8c11 Additive Manufacturing Micro SLM (Selective Laser Melting) E100.C14 912 Additive Manufacturing Space-Resolved Measurement of the Shielding Gas Flow E100.A14 10b in L-PBF Machines13 Additive Manufacturing Additive Manufacturing of Pure Copper with a Green Laser E100.A14 10c Beam Source for Electrotechnical Applications13 Additive Manufacturing Multi Metal and Alloy Concepts by Laser Metal Deposition E100.B12 1131 Additive Manufacturing Support-Free Photo-Polymerization with “TwoCure” E321 2932 Additive Manufacturing Laser-Based Production of Embedded Sensors E313 30b35 Additive Manufacturing Cladding Head with Coaxial Wire Feeding for Laser Metal E302 33 Deposition (LMD) 37 Additive Manufacturing Robotic Systems in Additive Manufacturing with Laser Material E100.A04 35 Deposition (LMD) 38 Additive Manufacturing Selective Laser Deposition of Conducting Paths E100.B06 38a on Electronic Devices45 Additive Manufacturing Additive Manufacturing of a Guide Vane Cluster – Product DPP E.01.2 44a Development Leads to Series Production Readiness 45 Additive Manufacturing Aachen Center for 3D Printing – Powder Bed Fusion DPP E.01.2 44b of XL Components46 Additive Manufacturing Institute for Toolless Fabrication DPP E.01.2 44c48 Additive Manufacturing The Missing Link: Aconity3D between Research and Industry DPP 1.01 47a48 Additive Manufacturing Digital. Additive. Production. DPP 1.01 47b51 Additive Manufacturing DPP Direct SLM Turbine Joint Laboratory DPP 1.14 51a51 Additive Manufacturing Thermo-Optical Modeling of Optics for L-PBF DPP 1.14 51b52 Additive Manufacturing Micro-Powder Bed Fusion (µ-PBF) - Extremely High-Resolution DPP 1.14 51c for Small Scaled Applications 53 AdditiveManufacturing UnifiedProgrammingEnvironmentforAdditiveand DPPAtrium 52c Subtractive Manufacturing54 Additive Manufacturing SLM Solutions Group AG – DPP Direct: Series Production with SLM DPP Atrium 52e55 Additive Manufacturing ACunity – Sino-German R&D Platform for Advanced Manufacturing DPP Atrium 52f55 Additive Manufacturing ACAM – Your Partner for Additive Manufacturing DPP Atrium 52g22 Cutting In-Situ Diagnostics System for Laser Cutting E100.C02 24a22 Cutting Processing of FRP – Cutting and Joining of Hybrids E100.C02 24b39 Cutting High-Speed Cutting and Welding E100.B06 38b20 Drilling Simulation Software Assisted Process Development for Laser Drilling E160.3 2243 Drilling Helical Drilling of Three-Dimensional Shaped Holes U102.1 42b Using Ultrashort Laser Pulses 16 EUV and Plasma Technology EUV Application Laboratory E044.1 1714 Generative Methods Customized Powder Feeding Nozzles for Powder-based Laser E100.A10 12 Material Deposition 37 Generative Methods Application of Adapted Powder Nozzles to Areas E100.A05 36 of Limited Access by Laser Metal Deposition (LMD) 16 Joining Laser Micro Welding of Copper and Aluminum with E032 18a Image Processing17 Joining Networked, Adaptive Production of Laser Welded Battery Modules E032 18b17 Joining Green Light is for Copper to Melt Away E032 18c32 Joining Laser Impulse Metal Bonding (LIMBO) E310 31a33 Joining Laser Ribbon Bonding for Power Electronics E310 31b33 Joining LaserTAB:MoreEfficientandPreciseElectricalContactsThanks E310 31c to Human-Robot Collaboration 34 Joining Absorber-Free Laser Welding of Transparent Polymers E310 31d34 Joining Joining of Fiber Reinforced Plastics (FRP) and Metal E304 3239 Joining High-Speed Cutting and Welding E100.B06 38b40 Joining Issues in Welding Ultrahigh Strong Dual Phase Steels E100.B07 39b40 Joining Laser Beam Welding of Ultrahigh Strength Dissimilar Welds E100.B07 39c

1

LASER TECHNOLOGY L IVE – AKL’18LASER TECHNOLOGY L IVE – AKL’18

32

Fraunhofer Institute for Laser Technolgy ILT With500employeesandmorethan19,500m²netfloorspacetheFraunhoferInstitute for Laser Technology ILT is worldwide one of the most important development and contractresearchinstitutesofitsspecificfield.Theactivitiescoverawiderangeofareassuch as the development of new laser beam sources and components, precise laser based metrology, testing technology and industrial laser processes. This includes laser cutting, caving, drilling, welding and soldering as well as surface treatment, micro processing and rapid manufacturing. Furthermore, the Fraunhofer ILT is engaged in laser plant technology, process control, modelling and simulation as well as in the entire system technology. We offer feasibility studies,processqualificationandlaserintegrationincustomerspecificmanufacturinglines. The Fraunhofer ILT is part of the Fraunhofer-Gesellschaft, with 72 institutes, more than 25,000 employees and an annual research budget of more than 2.3 billion euros.

Contact PersonDipl.-Phys. Axel BauerPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 1Entrance

CENTRAL INFORMATION

Chamber of Industry and Commerce Aachen (IHK Aachen) As the representative organisation for companies, Aachen Chamber of Industry and Commerce is the political lobbyist, mediator and advocate for the local business community of 78,000 companies in the Aachen region. As a customer-focused provider of services to the business community, we offer pre-market services for new and estab-lished companies. Our goal is to help others to help themselves. As a political lobbyist, we are strong advocates for a market-based legislative and regulatory environment which is conducive to small and medium-size enterprises. We are opposed to policies which favour a single industry and are committed to the commongoodofthebusinesscommunity.Thoughpoliticallyactive,wearenotaffiliatedwith a political party. As independent arbitrators, we support fair business practices by offering a range of services for alternative dispute resolution and prevention. This reduces court caseloads and helps to ensure that the wheels of commerce turn smoothly.

Our mission is clear: we work for our members and for the success of their businesses.

Contact Person IHK AachenDept. Innovation, Environment and IndustryPhone +49 241 [email protected]

BOOTH 2aEntrance

CENTRAL INFORMATION

Page Topic Short Description Location Booth 41 Joining Welding of LMD-Produced 2.4682 and Wrought 2.4630 E100.B07 39d Dissimilar Joints 7 Laser and Laser Optics Inner Processing Optics and Powder Feed Nozzles E100.C10 514 Laser and Laser Optics Inverse Laser Drilling: High Aspect Ratio Micro Structuring E103.2 13 of Dielectrical Materials 15 Laser and Laser Optics Directly q-switched High-Power Resonator Based on XLMA-Fibers E103.1 1518 Laser and Laser Optics Pulse Energy Scaled Single Frequency Laser E053 19a for Future Lidar Applications 18 Laser and Laser Optics 2-µm Laser Beam Source Developments E053 19b19 Laser and Laser Optics An Automated Setup for Measuring Laser-Induced E053 19c Damage Thresholds 24 Laser and Laser Optics Multiphysical Modelling of High-Power Diode Lasers E317 26a24 Laser and Laser Optics Key Optical Components for Rugged Laser Systems E317 26b25 LaserandLaserOptics High-StabilitySingle-FrequencyYbFiberAmplifierforNext E317 26c Generation Gravity Missions 25 Laser and Laser Optics Optical System for the Independent Positioning of Multiple E317 26d Laser Beams26 Laser and Laser Optics Model-Based Assembly of Optical Systems E317 26e26 Laser and Laser Optics Fiber Bragg Gratings for Frequency Stabilization of Diode Lasers E317 26f27 Laser and Laser Optics Coaxial Process Monitoring through f-Theta Lenses E317 26g27 Laser and Laser Optics Compact Laser Cutting Head with High-Power Optics E317 26h Made of Synthetic Monocrystalline CVD Diamonds 28 Laser and Laser Optics Dense Wavelength Combining and 35 µm Fiber Coupling E317 26i of High-Power Laser Diodes28 Laser and Laser Optics LIDAR System for Applications in the Automotive Industry E317 26j29 Laser and Laser Optics Development of Ultrafast Lasers with multi-kW Average Power E318 2735 Laser and Laser Optics Photonic Sources and Components for Quantum Technologies E316 34a36 Laser and Laser Optics Direct Generation of Laser Radiation in MIR E316 34b36 Laser and Laser Optics Lasers and Frequency Converters with Customized Wavelengths E316 34c from UV to MIR46 Laser Components Tailored Molds and Optics DPP E.02.1 45a19 Life Science Laser Assisted Bioprinting by LIFT and IR Laser Sources E055.2 2015 Micro Technology USP-Laser Processing with High-Repetition Rates E112.3 1430 Micro Technology Machining of 3-Dimensional Workpieces with Simultaneous E160.02 21 Movement of 5 Mechanical and 3 Optical Axes21 Micro Technology Combination of Short and Ultrashort Pulse Laser Processing E100.A02 23a for Productive Mold Tool Texturing41 Micro Technology Glass Frit Sealing by Laser Radiation E100.A07 4043 Micro Technology High-Precision Ultrashort Pulsed Laser Micro Structuring U102.1 42a by Means of Multibeam Processing 44 Micro Technology Roll-to-Roll Laser Patterning and Simultaneous Encapsulation U120.1 42c44 Micro Technology Processing Transparent Dielectrics with Ultrashort Pulsed DPP E.01.3 43 Laser Radiation50 Micro Technology 3D In-Volume Micro Structuring Fundamental Research Lab DPP 1.12 4950 Micro Technology LightFab 3D Printer for Precision Glass Devices DPP 1.16 50 23 Modeling and Simulation Modeling and Simulation of Cutting and Welding Main Hall 25a23 Modeling and Simulation Modeling and Simulation of Pulsed Laser Ablation and Drilling Main Hall 25b49 Modeling and Simulation Beam-Shaping Strategies to Generate Adapted Spatial and DPP1.03 48a TemporalTemperatureProfilesinLaserHeatTreatment53 Modeling and Simulation Development of Algorithm-based Lattice Structures in 3D DPP Atrium 52b Metal Printing 49 Solid State and Diode Laser VCSEL Sources for Industrial Thermal Processing DPP 1.03 48b5 Surface Treatment Laser-Based Production of Polymeric Coatings In Front of Entrance 3 for Tribological Applications8 Surface Treatment Extreme High-Speed Laser Material Deposition (EHLA) – E100.C11 6b Joseph von Fraunhofer Prize 201716 Surface Treatment Laser-Based Inline Functionalization of Printed Gold Layers E107 1631 Surface Treatment Surface Functionalization by VCSEL Technology E313 30a38 Surface Treatment Local Laser Heat Treatment of Ultrahigh Strength Steel and E100.A06 37 Cold Rolled Blanks 42 Surface Treatment Manufacturing of Glass Optics by Laser Ablation and Polishing U120.1 41a42 Surface Treatment Laser Polishing of Metals U120.1 41b47 Surface Treatment Application Adapted Freeform Optics for Surface Treatment DPP E.02.1 45b7 System Technology Quality Assurance for Laser Metal Deposition E100.C11 6a12 System Technology Process Monitoring for 3D-Printing by Selective Laser Melting SLM E100.A14 10a21 System Technology USP-Laser Processing as a Part of a Fully Connected, Adaptive E100.A02 23b I4.0 Process Chain 29 System Technology New Approach in Seam Tracking by Texture-Based Image Processing E327 28a30 System Technology System for Closed-Loop Control of Laser Spot Position on Seam E327 28b30 System Technology Process Monitoring of Welded FRP Tapes with IR Technology E327 28c39 SystemTechnology ArtificialIntelligenceProcessMonitoringforLaserWeldingProcesses E100.B07 39a54 System Technology Fraunhofer Institute for Production Technology IPT DPP Atrium 52d at Research Campus DPP

OVERVIEW PRESENTATIONS


54

Laser-Based Production of Polymeric Coatings for Tribological Applications

Multiple applications are predominantly affected by friction and wear stress and, therefore, represent a substantial challenge for the components being used. Oftentimes, theenduranceandtheefficiencyofthesecomponentscanbeenhancedbymeansofapplication-specifictribologicalcoatings.Forenginecomponentslikepistonsorbearingshells made of Aluminum or Steel, current coatings based on sliding lacquer do not meet increasing requirements, particularly regarding temperature resistance and wear protection. Coatings based on high-performance polymers like PEEK represent an alter-native to these coatings. Due to the high melting temperature of PEEK (340 °C), furnace-based coating processes result in a tremendous energy input and thermal load on the base material. Hence, a consortium led by the Fraunhofer ILT is developing a laser-based processthatsignificantlycontributestoincreasingenergyefficiencybyimplementingalocally and temporally controlled energy input with immensely reduced interaction times.

Contact Person M. Sc. Hendrik Sändker Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 3In front of Entrance

SURFACE TREATMENT

Heinrich Hertz Satellite

The Heinrich Hertz satellite mission is designed to allow for testing of new satellite communicationtechnologiesontheirsuitabilityinspace.In-orbitverificationminimizesthe risk of failure of such technologies for future satellite missions.Inaddition,HeinrichHertziscarryingsome20scientificandindustrialexperimentsinvolving communications, antenna and satellite technologies. The project will demons-trate Germany’s capabilities in satellite communications.The Federal Ministry of Defense (BMVg) hosts its own communication payload. Themilitaryandscientificpayloadsarephysicallyseparated.Consequentlythecostsfor the satellite platform and launch can be shared by the Federal Ministry of Defense and the Federal Ministry of Economic Affairs and Energy.The mission is being implemented by the DLR Space Administration on behalf of the Federal Ministry for Economic Affairs and Energy (BMWi) with participation of the Federal Ministry of Defense (BMVg).

Contact PersonLeslie ZeidlerPhone +49 [email protected] Zentrum für Luft- und Raumfahrt e.V. (DLR)

BOOTH 4aEntrance

SPECIAL EXHIBIT

AKL e.V. – Aix Laser People ArbeitskreisLasertechnikAKLe.V.isaregisterednon-profitassociationformedin1990bya group of companies and private individuals aiming to pool their experience and conduct joint public – relations activities in order to spread the use of laser technology in industry andpromotethesharingofscientificideas.The“InnovationAwardLaserTechnology”aims to reward excellent achievements in applied research and outstanding innovation inthefieldoflasertechnologyandtoshineaspotlightontheirauthors.In2017,176laser experts and enthusiasts were signed up as active members of the AKL network.

The association’s activities include disseminating information on innovations in laser technology, organizing conferences and seminars, compiling educational material dealing with laser technology, stimulating the interest of future young scientists, and providing advice to industry and research scientists on questions relating to laser technology.

Contact PersonDr. Hartmut Frerichs (General Secretary AKL e.V.)Phone +49 241 [email protected] Lasertechnik AKL e.V.

BOOTH 2bEntrance

CENTRAL INFORMATION

ELI e.V. – European Laser Institute Optical technology is taking an increasing hold on all domains of industry and science. Europealreadypossessesastrongpositioninthisfieldbyvirtueofitsnumerousexpertsand excellent research and development facilities. Nevertheless, it has been realized that there is an urgent need to link the existing sources of know-how and expertise, and to enhance the performance of joint research activities. Consequently, the European Laser Institute(ELI)hascreatedanefficientplatformbringingtogetherthenecessarycompe-tence and knowledge on optical technologies. By promoting technology transfer within Europe, ELI aims to enhance the international lead of European industry and research in thefieldoflasertechnologyandphotonics.Byworkinginclosecollaborationwithexistingnational and international organizations, the ELI network of industrial and academic researchinstitutionshelpstoinfluenceR&DpolicyonanationalandEuropeanlevel.

Contact PersonDr. Alexander OlowinskyPhone +49 241 [email protected] Laser Institute ELI e.V.

BOOTH 2cEntrance

CENTRAL INFORMATION


76

Inner Processing Optics and Powder Feed Nozzles IXUN Lasertechnik GmbH develops and delivers customised laser optics (in particular, inner processing optics) as well as powder and protective gas nozzles for all laser beam sources for processing (laser hardening, alloying, joining and laser cladding/coating) of outer and inner contours. With know-how and long-term experience in the sector of surface processing with laser radiation, IXUN Lasertechnik GmbH offers individual solu-tions for processing of single parts and mass production components. Range of services: Laser Cladding, Laser Hardening, processing of individual and series parts, pre- and post-processingfordeliveryofpre-finished,laser-processedcomponents,feasibilitystudies,consultation for the development of custom laser plant concepts, support and consultation for production ramp-up and problematic cases.

Contact PersonDr.-Ing. Khudaverdi KarimovPhone +49 241 [email protected] Lasertechnik GmbH

BOOTH 5E100.C10

LASER AND LASER OPTICS / ADDITIVE MANUFACTURING

Quality Assurance for Laser Metal Deposition The quality of additive manufactured components and coatings by Laser Metal Depo-sition (LMD) is highly dependent on reproducible setups and process stability. High per-formancepartscanonlybemanufacturedfreeofdefectsinadefinedprocesswindowin which small deviations already change the process result. For this reasons, there is a great necessity to control and document process variables and to monitor the process itself. At AKL’s Laser Technology Live a system will be demonstrated that has capabilities in supporting and documenting the process setup as well as monitoring the thermal emissions of the process and controlling the process stability. One important feature is the measurement of the entire powder gas jet and the characterization of powder jet nozzles. Potential applications include all activities in the sector of LMD for which the exact knowledge of the process setup and stability is required like Extreme High-speed Laser Material Deposition (EHLA).

Contact PersonDipl.-Ing. Stefan Mann Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 6aE100.C11

SYSTEM TECHNOLOGY

The German-French Climate Mission MERLIN The German-French climate mission MERLIN will measure methane levels in the Earth’s atmosphere presumably from 2023 onward. From an altitude of approximately 500 kilometers, the satellite MERLIN will use a Lidar instrument, being developed in Germany, to detect this extremely potent greenhouse gas. The platform, carrying the instrument, is a development by France’s National Centre for Space Studies CNES. TheGroundSegmentiscommonlydevelopedinGermanyandFrance;thescientific data will be retrieved, processed and archived in France.The three-year mission is aimed at producing a global map of atmospheric methane concentrations. Among other things, this will provide information on the main regional sources of methane and the areas in which the greenhouse gas is removed from the atmosphere (sinks).The DLR Space Administration is responsible for the German contribution to MERLIN Mission with funds from the BMWi.

Contact PersonDr. Matthias AlpersPhone +49 228 [email protected] Zentrum für Luft- und Raumfahrt e.V. (DLR)

BOOTH 4bEntrance

SPECIAL EXHIBIT

MERLIN Laser Source 3D Model Fraunhofer ILT is developing the Laser Optical Bench, the core element of the laser-beam source for the Franco-German-climate mission MERLIN (Methane Remote Sensing LIDAR Mission). Starting in 2023, this bench – as part of the LIDAR system – shall emit laser pulseswithspecificproperties;thesepulseswillhelpmeteorologistsmakeconclusionsabout the methane content of the atmosphere by a measurement of the backscattered light between satellite and ground. Since the complex laser will be used under vibrations and temperature changes, durable and robust construction technology is required. In order not to destroy the sensitive laser optics by molecular contamination, outgassing organic materials – such as adhesives and plastic-based insulation – cannot be used at all. The MERLIN laser transmitter is based on the technology platform FULAS (FUture LAser Systems) which has been developed by Fraunhofer ILT in cooperation with Airbus Defence and Space GmbH to meet the above mentioned requirements. The full-scale 3D Model shown here visualizes the design of the MERLIN laser transmitter including the pressurizes housing provided by Airbus Defence and Space GmbH.

Contact PersonDipl.-Phys. Jörg LuttmannPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 4cEntrance

SPECIAL EXHIBIT


98

Laser-Powder Bed Fusion of Biodegradable Materials Today, most commercial implants are made from titanium alloys. However, for many applications biodegradable implants would enable a superior treatment. Biodegradable implants can dissolve in the human body and subsequently be replaced by the patient’s own bone tissue. By using biodegradable solutions, transplantations of autologous bone could be drastically reduced and many patients could be saved from living with a foreign implant and its side effects. Laser-powder bed fusion (L-PBF) enables manufacturing scaffold-like structures with designed interconnected porosity tailored to the patient’s indication. Thereby, new tissue can grow through the whole implant and optimize the resorption process. The implant is reinforced by new tissue during the degradation and degradationproductscanbeefficientlyremoved.However,biodegradablematerialsarevery challenging to process by L-PBF. This booth will demonstrate the progress in manu-facturing biodegradable implants from very challenging materials such as magnesium, iron or zinc alloys as well as polymer ceramic composites.

Contact PersonDipl.-Phys. Lucas JauerPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 7bE100.C12.2

ADDITIVE MANUFACTURING

Sensor Integration So called “smart parts” are a key enable for Industrie 4.0. These parts feature electronics or measurement devices that allow the part to communicate with the user. The additive manufacturing technology Laser-Powder Bed Fusion (L-PBF) offers new ways to integrate electronics into parts. Fraunhofer ILT developed a process chain to fully integrate pressure sensors and thermometers into metal parts, allowing the user to monitor the parts stress condition and thermal load in real-time. In contrast to other integration methods, L-PBF integrated sensors have a material connection with part, which improves life span, response time and accuracy of the measurement values.

Contact PersonDipl.-Ing. Simon VervoortPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 7cE327


Extreme High-Speed Laser Material Deposition (EHLA) – Joseph von Fraunhofer Prize 2017 Extreme High-speed Laser Material Deposition (EHLA) was developed at Fraunhofer ILT in Aachen in close cooperation with RWTH Aachen University to overcome the draw-backs of conventional coating methods such as hard chrome plating, thermal spraying and other cladding methods in an economical way. With EHLA metallurgically bonded layersmeasuredintenthsofamillimetercanthusbeflexibly,efficientlyandquicklyapplied to large surfaces. Particularly EHLA provides an alternative to chromium (VI) coatings, which require an authorization as of September 2017. For the environment friendly alternative, the novel technology was awarded with the Joseph von Fraunhofer Prize in 2017. Besides coating applications, EHLA also offers several other innovative and promising possibilities – i.e. in the manufacturing of new parts. At AKL’s Laser Technology Live two systems from Hornet Laser Cladding are demonstrated, which are specially designed for EHLA of rotationally symmetric work pieces.

Contact PersonDipl.-Ing. Thomas SchopphovenPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 6bE100.C11

SURFACE TREATMENT

Automatable Support Removal and Surface Smoothing Approach for L-PBF-manufactured Parts Made of Aluminum Alloys A major challenge to economical use of Laser-Powder Bed Fusion in industrial mass pro-duction is the great effort for the removal of support structures. According to the state of the art, the support structures are generally removed manually which requires a great expenditure of time as well as expense and therefore isn’t suitable for mass production. A promising approach for the automation of support removal is the chemical ablation (etching). The components can be separated from the support structures by immersion in an etching solution. Since they can be treated as bulk material in batches the systems engineeringisverysimpleandthereforecost-efficient.CurrentinvestigationsatFraunhoferILT show the general feasibility for the complete removal of internal and external supported surfaces from L-PBF parts made of Aluminum Alloy and post-processed via this method. Furthermore a surface smoothening effect could be proven.

Contact PersonM. Eng. Tobias Schmithüsen Phone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 7aE100.C12.2



1110

Powder Bed Fusion with Diode Laser Laser-Powder Bed Fusion (L-PBF) is an established Additive Manufacturing (AM) process for the production of metal components. Despite its great potential, the technology has not yet arrived in many small and medium enterprises (SMEs). The Aachener Center for 3D Printing, a collaborated AM group formed by the Fraunhofer ILT and the Aachener University of Applied Sciences (FH Aachen), was foundet to analyze the needs of SMEs regarding the integration of metal AM technology within their own companies. In context of this cooperation a PBF machine was build, which uses low cost diode lasers as beam source instead of complex and expensive laser scanning systems. The innovative machine design is highly adaptable and can be offerd at a fraction of the cost of a conven-tional PBF system, what makes the L-PBF technology affordable to a wider range of users and offers especially SMEs the access to this technology. The described machine will be further developed and sold as part of a spin-off company (see LMI – Laser Melting Innovations).

Contact PersonM. Eng. Dawid ZieburaPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 8cE100.C13


Micro SLM (Selective Laser Melting) IQ evolution is a developer of special cooling devices for electronic components and diode lasers by using generative manufacturing procedure SLM: • Our products are micro cooler for high-power laser diodes, cooler for power electronics or LED as well as other complex 3D structures •Ourmicrocoolersareleadingf.e.toasignificantincreaseinthelifetime of the laser bars compared to the current copper based cooling technology (the new materi als used here are not exposed to corrosion and erosion) • We have special know-how in the Selective Laser Melting process and machines as well as in using special materials, pure materials and custom made material compounds • We are able to produce micro structures from 80 µm up

Contact PersonDr. Thomas EbertPhone +49 241 [email protected] Evolution GmbH

BOOTH 9E100.C14


LMI – Laser Melting Innovations At this year’s “Laser Technology Live” LMI will demonstrate the Alpha140 a game-changer in terms of funcionality. Unlike most other metal 3D printers, the Alpha140 works with a diode laser beam source. The optical system is mounted on a Cartesian axis system and positioned over the build platform by high dynamic servo drives. The costefficientplantdesigncanthereforeeasilybescaledintermsofthebuildvolume.In addition, the machine can be offeres at a fraction of the price of an conventional SLM machine. For those reasons the Alpha140 is especially suitable for companies who enter the metal Additive Manufacturing market. With more than 20 years of experience inthefieldofAdditiveManufacturing,ourteamhasin-depthexpertiseintheareasofplant and process engineering as well as in training and consulting services. Our mani-fold competence allows us to regularly challenge the status quo and set new standards. Curious for more? Come visit us!

Contact PersonM. Eng. Mirjam KnothePhone +49 241 [email protected] – Laser Melting Innovations GmbH & Co. KG

BOOTH 8aE100.C13


Scalable Machine Concept for Laser-Powder Bed Fusion Laser-Powder Bed Fusion (L-PBF) is becoming increasingly important in industrial pro-duction. One of the decisive factors is the scalability of the build volume. For large build volumes, established inert gas suction strategies are no longer effective. Therefore, current research focuses on small, movable processing heads with a local shielding system, which ensures a constant stream of inert gas at every processing point for build volumes of any size. Following this approach, it is easier than before to adapt the build volume to the respective application, since there is no need to adjust the shielding gas system or the optical system. Based on this concept, a new L-PBF laboratory system with an effective utilizable build volume of 1,000 mm x 800 mm x 500 mm was built. This system is being investigated within the Fraunhofer focus project “futureAM”.

Contact PersonM. Sc. M. Sc. Christian Tenbrock Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 8bE100.C13



1312

Additive Manufacturing of Pure Copper with a Green Laser Beam Source for Electrotechnical Applications In the last few years, Fraunhofer ILT has expanded and demonstrated the state-of-the-art for processing copper alloys, e.g. CuCr1Zr, with LPBF. Especially for electrotechnical appli-cations, pure copper, however, is more important due to its better electrical conductivity. Processing it faces two challenges: the material’s high thermal conductivity and its high degreeofreflectionforlaserradiationatawavelengthofλ = 1030 nm. Switching to green light at a wavelength of λ = 515 nm means that theoretically less laser power is needed to ensure a stable process. Furthermore, the laser beam can be focused more precisely, and different melt pool dynamics guarantee smoother welding tracks. Moreover, in the ongoing project, ILT is building a laboratory setup and develops a proces strategy to reach a density of > 99.5 percent in samples as well as in bigger industrial relevant components. Benefitsofusingadditivemanufacturingfore.g.inductioncoilshavealreadybeenprovenfor the copper alloy CuCr1Zr and are promising for the ongoing developments with pure copper, as it could be the next step in industrial

Contact PersonM. Sc. Daniel HeußenPhone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 10cE100.A14


Multi Metal and Alloy Concepts by Laser Metal Deposition Laser Metal Deposition (LMD) can be used as an additive manufacturing process by cladding layer upon layer. The result is a near net-shape component with almost 100percentdensityandapropertyprofilewhichmeetsorexceedsthespecificationsoftheusedmaterialduetothefinemicrostructurecreatedbythehighcoolingratesduringLMD. The size of the components is only limited by the handling system. In contrast to powder bed based technologies LMD offers the possibility to build up on existing parts as well as realizing new material concepts by e.g. establishing graded properties through gradual addition of different powders or build-up of lightweight hybrid components consisting of various alloys. Preheating and low oxygen atmosphere are often mandatory, especially for manufacturing brittle materials as e.g. intermetallics. Potential applications are the production of functional prototypes and small batch parts. LMD can also be used to modify components for a more individualized production when small numbers of derivatives are required.

Contact PersonM. Sc. Silja-Katharina Rittinghaus Phone +49 241 8906-8138siljakatharina.rittinghaus@ilt.fraunhofer.deFraunhofer-Institut für Lasertechnik ILT

BOOTH 11E100.B12


Process Monitoring for 3D Printing by Selective Laser Melting SLM Process control for Laser-Powder Bed Fusion is seen as one of the key enablers for future series production of L-PBF parts. Fraunhofer ILT shows a laboratory system for materials researchandprocessdevelopmentwhichprovidesaflexibleplatformforresearchandand validation.Asalaboratorysystem,theopticaltrainisspecificallydesignedandoptimisedforprocesscontrol. It uses a pre-focus system in combination with a fast closed loop scanning system and interfaces to a set of coaxially coupled sensors to observe the melting process. Pyrometric sensors detect radiation from the melt pool at 100 kHz and a camera system provides a visual image of the processing zone while the beam position is recorded synchronously. The signals are visualized as a so called emission map which provides a spatial resolution of 100 micron even at scanning speeds of 10 m/s. As such, the monitoring system allows the detection of deviations in the thermal emission during the L-PBF process indicating potential process instabilities or defects in the L-PBF parts.

Contact PersonM. Sc. Dipl.-Ing. (FH) B. Eng. (hon) Ulrich Thombansen Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 10aE100.A14

SYSTEM TECHNOLOGY

Space-resolved Measurement of the Shielding Gas Flow in L-PBF Machines

In addition to process parameters such as laser power, scanning speed, etc., the shielding gasflowinSLMsystemsstronglyinfluencesthequalityofthecomponentsgenerated.Ageneralcharacterizationoftheflowviathevolumeflowisnotsufficient,however;moredecisiveisthelocalflowprofileabovetheconstructionplatform.Inordertobetterunderstandhowtheshieldinggasflowcorrelateswiththeresultingcomponentquality,amethodtomeasuretheshieldinggasflowwithinL-PBFmachineswithhighresolutionin space has been developed. Based on thermal anemometry parameters such as the localflowspeedandturbulencecanbemeasuredandcorrelatedtothepartqualityatthecorrespondinglocation.Easilyadaptableinitsdimensionsthesystemcanbefitintomost commercial machines and is made to be operated under near-processing conditions. Contact PersonDipl.-Ing. Maximilian SchniedenharnPhone +49 241 8906-8111maximilian.schniedenharn@ilt.fraunhofer.deFraunhofer-Institut für Lasertechnik ILT

BOOTH 10bE100.A14



1514

USP-Laser Processing with High-Repetition Rates Ultrashort pulsed (USP) laser processing provides a better surface quality, higher precision and less thermal impact compared to processing using longer pulsed laser radiation. Nevertheless, USP processes are still not established for broad industrial applications due to their low productivity. In order to improve the processing speeds, the utilization of high power USP-Laser systems in the range of hundreds of Watts of average power and high repetition rates (several MHz) is a promising approach. However, for these pro-cesses high scanning speeds are necessary to ensure pulse separation or constant pulse overlap. For this purpose a polygon scanning system with scanning speeds up to 360 m/s atfocallengthof163mmisapplied.Toablatedefined2.5Dstructuresthepulsedlaserradiation is modulated synchronously to the position of the laser spot on the workpiece surface. With this combination of high power laser and high speed scanner ablation rates of more than 30 mm³/min for stainless steel can be achieved.

Contact PersonM. Sc. Dipl.-Ing. (FH) Benedikt BornschlegelPhone +49 241 [email protected] Aachen University – Lehrstuhl für Lasertechnik LLT

BOOTH 14E112.3

MICRO TECHNOLOGY

Directly Q-switched High-Power Resonator Based on XLMA-Fibers We present a simple approach to achieving nanosecond pulses from a directly q-switchedhigh-powerresonatorbasedonextra-largemodearea(XLMA)fiberswith a beam quality factor M² < 15. The average output power exceeds 500 W and has been demonstrated for repetition frequencies between 50 - 100 kHz. The resonator consists ofasinglefiberq-switchedwithsolderedPockels-cellswhichexhibitaveryhighcontrastratio leading to output pulses down to about 10 ns and peak powers up to > 250 kW at 1064 nm wavelength.

Contact PersonDipl.-Phys. Martin GiesbertsPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 15E103.1

LASER AND LASER OPTICS

Customized Powder Feeding Nozzles for Powder-based Laser Material Deposition Powder nozzles are key components for powder-based laser material deposition. The way the additive material is fed into the melt pool on the substrate is having a decisiveinfluenceonthedimensionalaccuracyofthedepositedmaterial,thequality of the layers or volumes produced, as well as the cost-effectiveness of the process. Based on the basic principles of lateral or coaxial powder feeding for cladding processes, the Fraunhofer Institute for Laser Technology ILT is developing customized solutions for powder feeding nozzles that meet the high demands for precision for this technology. A new development for extreme high-speed laser material deposition, known by its German acronym EHLA, is demonstrated – a coaxial powder nozzle with exchangeable nozzletips,whichallowstoflexiblychangeworn-outordamagednozzletips.

Contact PersonDipl.-Ing. (FH) Stefan JungPhone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 12E100.A10

GENERATIVE METHODS

Inverse Laser Drilling: High Aspect Ratio Micro Structuring of Dielectrical Materials

Inverse Laser Drilling is a laser microstructuring technique to drill geometries of high aspect ratio into dielectric materials like glass. The sample is placed on a vertically movable translation table with a polished surface facing upwards. The laser beam is focused through the top surface onto the bottom surface of the bulk. The beam is deflectedbyscanningmirrorsinthehorizontalplane,thiswaythedesiredgeometry’sfirstlayerisablated.Bymovingthetranslationtableandablatinglayersstepbystepthe entire geometry can be ablated or “drilled”. Drilling of holes with aspect ratios < 1:250 has been demonstrated.Due to a patented improvement of the drilling process chipping can almost totally be avoided. The polished surface remains unaffacted just to the edge of the opening. Thisallowsformanufacturingspatialfiltersormirrorswithsmallopeningsforalmostlossless geometric separation of laser beams.

Contact PersonDipl.-Phys. Dipl.-Volksw. Dominik EsserPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 13E103.2



1716

and aluminum with its lightweight ability is interesting for multiple applications. The different melting temperatures and thermal conductivity as well as the occurance of inter-metallic phases are challenges for the laser welding process. Using high brilliant laser beam sources in combination with a spatial power modulation (superposition of linear feed with a circular oscillation), weld seams with high quality can be performed. Additionally, a scanner optics with image processing ensures a weld positioning with high precision.

Contact PersonM. Sc. Sören Hollatz | Phone +49 241 [email protected] | Fraunhofer-Institut für Lasertechnik ILT

Networked, Adaptive Production of Laser Welded Battery Modules The international center “Networked, Adaptive Production” deals with the development for the ongoning digitalization of machines and production systems. Together with theFraunhoferIPTandIME,sixpracticalpilotlinesaresetup,dividedintothreefields:energy, mobility and health. In the pilot line “Battery”, the Fraunhofer ILT examines the adaptive design and production of battery modules. By using different cell types, suitable modulesareconfigurated,designedandmanufacturedinsmalltomedium-sizedquantities.As manufacturing technology for the connecting elements, laser welding and laser bonding are employed. The machines will be connected with a database server which collects data of the machines, process parameter, simulations and process monitoring.

Contact PersonM. Sc. Sören Hollatz | Phone +49 241 [email protected] | Fraunhofer-Institut für Lasertechnik ILT

BOOTH 18bE032

JOINING

Laser-Based Inline Functionalization of Printed Gold Layers The increasing functional integration in products within the electronics industry, charac-terized by the highest volumes, requires cost-effective processes which enable functional layerstobeproducedflexiblyandappliedselectively.Conventionalelectriccontactlayerslike gold are applied by electroplating, PVD, or CVD. These processes are resource-, cost- and time-intensive. Within this context, Fraunhofer ILT – in collaboration with Phoenix Contact and Heraeus – has developed a print- and laser-based process for the production of selective and robust gold layers for the use as electrical contact pads on industrial connectivity parts made from nickel-plated copper strip stock. This inline-capable process can also be used for the selective plating of electrical contact surfaces of various components.

Contact PersonM. Sc. Florian Fuchs | Phone +49 241 [email protected]|Fraunhofer-InstitutfürLasertechnikILT

BOOTH 16E107

SURFACE TREATMENT

EUV Application Laboratory The technological application of extreme ultraviolet (EUV) radiation is at the forefront of the modern science and is gaining more and more industrial relevance as the semi-conductor industry is making a switch from structuring with 193 nm (DUV) to 13.5 nm (EUV) wavelength. In the EUV Application Laboratory at Fraunhofer ILT/RWTH Aachen University, various highly promising applications are being explored and evaluated. The setup for ultra-high resolution EUV interference lithography suited for large area nano-scalestructuringisdemonstrated,aswellasanoveldark-fieldEUVdefectinspectionsystem for EUV Mask blanks with sub-50 nm defect size sensitivity. Additionally, the uniquelaboratory-basedmulti-anglespectroscopicEUVreflectometerisshown,whichallowstodeterminenotonlythethicknessofthinfilmswithsubnmprecisionbutalsotheirchemicalcomposition.Allsetupsarebuiltin-houseandareusingefficientandcompact radiation sources based on the Fraunhofer ILT developed technology.

Contact PersonDr. rer. nat. Serhiy Danylyuk | Phone +49 241 [email protected] Aachen University – Lehrstuhl Technologie Optischer Systeme TOS

BOOTH 17E044.1

EUV AND PLASMA TECHNOLOGY

Green Light is for Copper to Melt Away Copper has been established in our everyday life for quite some time and has become an indispensable part of our daily live. Cell phones, toothbrushes, rechargeable batteries, cars, are no longer conceivable without copper. Theweldingofcoppercomponentsisachallengeduetotheveryhighreflectionforinfrared wavelengths of conventional laser beam sources. Also the reproducibility of the welding process and the minimization of spatter formation are essential and in some cases problematic for industrial processes. The development of green lasers with a wavelength of 515 nanometers solves the problems that arise during copper welding with infrared lasers. Independently of the surface quality – ground, corroded, high roughness or extremely polished – copper welding seams can always be produced with constant top quality.

Contact PersonVahid Nazery Ghoneghany | Phone +49 241 [email protected] | Fraunhofer-Institut für Lasertechnik ILT

BOOTH 18cE032

JOINING

Laser Micro Welding of Copper and Aluminum with Image Processing Theongoingelectrificationleadstoanincreaseddemandofelectricalinterconnectionsof dissimlar materials. A combination of copper as a highly electrical conductive material

BOOTH 18aE032

JOINING


1918

An Automated Setup for Measuring Laser-Induced Damage Thresholds

This setup allows testing of optical components for usage in high-power laser systems with respect to laser-induced damage threshold (LIDT). The test facility conforms to ISO 21254 and can be adapted to a variety of laser parameters. It is currently equipped for testing at wavelengths of 1064 nm (up to 500 mJ) and 1645 nm (up to 100 mJ). The laser sources output single-frequency laser pulses at a beam diameter of ~ 400 µm withatemporallyandspatiallywell-definedpulseprofile.Thespecimencanbeplacedin a chamber and tested at different environmental conditions (process gas/vacuum/atmosphere). Testing capability at 2051 nm is currently under construction. The entire sample-handling (irradiation, sample pre- and postprocessing) takes place in a contained cleanroom environment class ISO 7 or better.

Contact PersonM. Eng. Robin LutumPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 19cE053


Laser Assisted Bioprinting by LIFT and IR Laser Sources Tissueengineerinngisanimportantfieldofresearchinourtimetomeettheneedsof our aging society. A promising technology in this area is bioprinting of living cells andscaffoldmaterialstogenerateartificialtissue.Laserassistedbioprinting(LAB)whichis presented here is a special technology for bioprinting providing high accuary for cell selection and positioning. LAB uses the contact free laser induced forward transfer (LIFT) technology. In earlier setups a UV laser source was used for LIFT. The UV light was absorbed by a titanium layer. The titanium forms a gas plume consisting of titanium nanoparticles which transfers the underneath lying gel and cell containing layer on a receiver slide. The new process presented here uses midinfrared laser irradiation to absorb the irradiation in water to transfer cells into standard microtiter plates without any titanium or other contaminating material. The new LIFTSYS®Workbench module can work under sterile conditions within a standard workbench. This technology will allow in the future to print either single cells for biopharmaceutical testing or tissue like structures for tissue engineering purposes.

Contact PersonDr. rer. nat. Nadine Nottrodt Phone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 20E055.2

LIFE SCIENCE

Pulse Energy Scaled Single Frequency Laser for Future Lidar Applications Inthefieldofatmosphericresearchlidarisapowerfultechnologytomeasureremotelydifferent parameters like gas or aerosol concentrations, wind speed or temperature profiles.Forglobalcoveragespacebornesystemsareadvantageous.Toachievehighlyaccurate measurements over long distances high pulse energies are required. A Nd:YAG-MOPA system consisting of a stable oscillator and two subsequent InnoSlab-based amplifierstageswasdesignedandbuiltasabreadboarddemonstrator.Overall,morethan 500 mJ of pulse energy at 100 Hz pulse repetition frequency at about 30 ns pulse duration in single longitudinal mode was demonstrated. Recently, different MOPA systemscomprisingasingleInnoSlabamplifierstageinthe100mJregimeweredesignedand built for current and future airborne and spaceborne lidar missions. In order to address the 500 mJ regime the established InnoSlab design was scaled geometrically.

Contact PersonM. Eng. Robin Lutum Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 19aE053


2-µm Laser Beam Source Developments Fraunhofer ILT has developed several laser beam sources with wavelengths around 2 µm basedonThulium-andHolmium-dopedfluoridecrystals.A200WcwInnoslablaserosillatorwithaline-shapedbeamprofileat1.9µmhasbeenbuiltandiscurrentlyusedforpumpingaHo:YLFInnoslabamplifiercrystal.Inrodgeometry,Tm:YLF-laserwith15 W (cw) at 1.9 µm and a Ho:YLF-laser with 8 W (cw) at 2.05 µm have been built. Additionally, q-switched laser pulses have been produced in a Ho:YLF laser oscillator. Up to 10 mJ at 100 Hz and 2.7 mJ at 1 kHz have been shown at 2051 nm. Currently, Ho:YLFInnoslabamplifierstagesareunderdevelopment,withwhichpulseenergiesinexcess of 50 mJ are aimed for. These laser sources are foreseen for usage in CO2-lidar systems and for LIDT-tests of optical components at 2 µm. There are, however, a number of applications of such beam sources in materials processing (e.g. of transparent materials) and health-care. Additionally, such lasers are commonly used as pump lasers for nonlinear frequency conversion into the MIR.

Contact PersonM. Sc. Philipp Kucirek Phone +49 241 8906-8108 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 19bE053



2120

Combination of Short and Ultrashort Pulse Laser Processing for Productive Mold Tool Texturing Surface functionality is an increasing and crucial factor for the success and acceptance of a product. Due to the structured surface products can gain additional functions. The most common way to create surface functionality in mass production are replication processes via structured mold tools. Industrial state of the art to generate microstructured molding tools is materials processing by means of nanosecond lasers. However, this technology is limited by the achievable surface quality: This leak of quality occurs due to melting of the processed material leading to rough contours, especially for intricate structures. In contrast, ultrashort pulsed laser radiation is not capable to achieve the required throughput rates, but it can be applied for ultra-precise ablation. Finding a way to combine picosecond and nanosecond pulsed laser processes, similar to mechanical roughingandfinishingprocess,isthegoaloftheresearchprojecteVerest.Here,ans-laserprocess with high ablation rate is applied to roughly generate the intended surface with high throughput. In a second step, the surface is processed by a ps-laser radiation togeneratefiner,morecomplexstructuresinthesamemachine.

Contact PersonM. Sc. Andreas Brenner Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 23aE100.A02

MICRO TECHNOLOGY

USP-Laser Processing as a Part of a Fully Connected, Adaptive I4.0 Process Chain An interconnected, self-adapting process chains that enable an automated lot-size one production represent a strong foundation of the fourth industrial revolution, Industrie 4.0.The ultrashort pulsed laser processing machine is a part of a production chain for assemb-ling individually developed automotive components in series. It is equipped with sensors for real-time process- and machine condition monitoring and is connected to the “Smart Manufacturing Network” via OPC-UA interface. A hybrid FPGA-PC-based system collects the required information with sample rates of up to 100 kHz. The multi-sensor approach combined with high sample rates yields a large amount of data of few tens to hundreds of gigabytes per structured workpiece. Combined with the information collected from the other machines in the process chain, this data will further be processed with Big Data analysis techniques in order to implement a real-time productivity-based decision-making as well as a reliable defect detection and prediction.

Contact PersonM. Sc. Milena Zuric Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 23bE100.A02

SYSTEM TECHNOLOGY

Machining of 3-Dimensional Workpieces with Simultaneous Movement of 5 Mechanical and 3 Optical Axes Solutions used in industry for path planning for laser texturing of three-dimensional components apply simple strategies (e. g. meandering scanning of the surface) which achieve acceptable machining times. At the same time these strategies are far below capability of the machines, as not all degrees of freedom of the available mechanical axes and the optical systems are exploit. Thus, one approach is to use all degrees of freedom, e. g. by simultaneous movement of all axes. With simultaneous minimization of the traverse paths, considerably shorter machining times can be achieved. As part of the joint project “Everest”, a procedure was developed to process 3D surfaces with the laser using a 5-axis Siemens NC and a 3-axis galvanometer scanner with simultaneous use of all 8 axes.

Contact PersonDipl.-Ing. Andreas DohrnPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 21E160.2

MICRO TECHNOLOGY

Simulation Software Assisted Process Development for Laser Drilling In order to manufacture drilling holes with certain geometrical properties such as inclina-tion, diameter and conicity a development process with subsequent evaluation of each hole might be required. With aid of accurate simulation models it is possible to predict thefinalholegeometryandthusminimizetheamountoftimeandresourceconsumingexperiments. However, most models require powerful work stations and often long calculationtimes.FraunhoferILThasdevelopedanimprovedandefficientsimulationsoftware which runs on handheld devices. It is able to instantaneously present the asymp-totic hole shape depending on relevant laser process parameters and material properties. By conveniently changing different process parameters a graphical cross-section of the holeinthepredefinedmaterialtypeandthicknessshowsnotonlytheshapebutalsothe entry and exit diameter.

Contact PersonDipl.-Ing. M.Sc. Stefan JanssenPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 22E160.3

DRILLING


2322

Modeling and Simulation of Cutting and Welding Laser cutting and welding are well established production technologies, which are rated by productivity and product quality in the industrial application. Physical modeling and numerical simulation hold the potential for cost-effective design optimizations. For laser cutting an interactive metamodel based on an approximate model has been developed, whichhelpstoanalyzetheinfluenceoflaserparameteronthecuttingquality.Inlaserwelding one important quality characteristic is the component distortion. The simulation of the heat distribution inside the component makes it possible to analyze the distortion depending on weld parameters. The automation and the acceleration of determining heat source parameters simplify theapplicationofsimulationtoolsandraisethecomputationalefficiency.Therefore,fastnumericalmethodsandoptimizationalgorithmswhichautomaticallyfindthemodelparameters on the basis of experimental data have been developed.

Contact PersonM. Sc. Christoph SchölerPhone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 25aMain Hall

MODELING AND SIMULATION

Modeling and Simulation of Pulsed Laser Ablation and Drilling Pulsedlasersareusedforapplicationseitherrequiringhighfluencesorbeinginneedto limit the continuous load (thermal, mechanical, electronic) for the involved materials. Industrial application cases investigated by modeling and simulation at Fraunhofer ILT mainly refer to the Laser Micro Jet technology (where a water jet is amongst others- usedforbeamguidingpurposes),theUSPablationandfilamentcuttingof(semi-transparent) dielectrics (e.g. glass) and the long-pulse drilling of metallic work pieces (e.g. turbine components). The industrial application of pulsed laser processing is established already. However, there are gaps in understanding the physical mechanisms involved in laser ablation, especially issues related to the realization of desired ablation contours and maximum ablation depth. This is where modeling and simulation can offer an appropriate gain in process understanding. The models elaborated for the demons-trated application cases give an insight how crater shape, morphology of the ablation front and damage within the material evolve.

Contact PersonDipl.-Phys. Torsten Hermanns Phone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 25bMain Hall


In-Situ Diagnostics System for Laser Cutting Instabilities of the laser cutting front cause loss of quality due to the formation of stria-tions.Forin-situ-diagnosisofthemeltingandsolidificationdynamicsinlasercutting,a trim-cut test bench was set up as a part of the SFB 1120 “Precision Melt Engineering”. During a trim-cut the laser beam is displaced relative to the original edge by less than a kerf width in the direction of the metal sheet. To maintain a guided supersonic gas jet pathalongthemeltfilmandtoenablethecuttingkerftobeobservedbyhigh-speedimagingduringtheprocess,themissingcutflankissimulatedbyatransparentreplace-ment edge. That procedure enables temporal and spatial in-situ diagnosis and analysis ofmeltflowdynamicsonthecuttingfront.Inthismanner,in-situ-visualizationofmulti-plereflectionsinsidecuttingkerfsispossibleforthefirsttime.Furthermore,thecalmingeffect on the melt dynamics as a result of a divergent laser beam is demonstrable. The knowledge gained in close cooperation between the Chair for Laser Technology LLT and the Fraunhofer Institute for Laser Technology ILT supports the further development of sophisticated and application-oriented beam shaping concepts to improve the achievable cut quality.

Contact PersonM. Sc. Dennis ArntzPhone +49 241 [email protected] Aachen University – Lehrstuhl für Lasertechnik LLT

BOOTH 24aE100.C02

CUTTING

Processing of FRP – Cutting and Joining of Hybrids Inproductionoffiberreinforcedplasticscomponents,reductionofcycletimeisoneofthe priority objectives to push its wide-spread use in mass production. End machining with lasers for trimming of components or cutting of holes overcomes limitations of mechanical processing due to induced forces and intense tool wear. The use of high power cw-lasers leads to high processing speeds. However, quality demands such as narrow heat affected zones(HAZ)andrectangularcutflanksrequirematerialandcomponentadaptedproces-sing and scanning strategies. High scanning speeds provided by a prototype scanner for multi-kW single mode laser radiation minimize the heat load at the cut edge. The example on display shows the trimming of a car roof bow, consisting of a hybrid material from aglassfiberreinforcedPolyamidewithunidirectionalcarbonfiberreinforcement,whichis processed in one working operation. Cooling times to avoid heat accumulation from scan to scan are integrated in a quasi-continuous operation of the cut path, superposing the fast scan of the laser beam and a slow movement of the work piece under the scanner. A second laser based process on this demonstrator is the joining of the composite to metal plates. A spongy micro-structure in the metal is achieved by ultrafast lasers, allowing to join metal and plastic via positive locking and adhesion.

Contact PersonDr.-Ing. Frank Schneider Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 24bE100.C02

CUTTING


2524

High-Stability Single-Frequency Yb Fiber Amplifier for Next Generation Gravity Missions As part of its Earth Observation program, the European Space Agency is overseeing missionstomeasurethegravitationalfieldoftheearth.Inordertoimprovethemeasure-mentresolutionfrompreviousmissions(e.g.GRACE),thisamplifierwasdevelopedtoexhibit a spectral bandwidth below 10 kHz at 1064 nm and to operate with extremely high stability for optical power as well as central wavelength. The beam source consists ofafiberamplifierdevelopedbyFraunhoferILT,whichscalesthesignalofanon-planarring oscillator to the desired output power, and a reference cavity developed by a project partner,whichstabilizesthelaserinitsfrequency.Theactivemediumoftheamplifier isapolarization-maintainingsingle-modefiberwithstepindexprofile.Bymeansof a photodiode and a customized, high-resolution electronics, the output power of the laser can be actively stabilized by modulating the pump power. The required output power of 500 mW could be successfully demonstrated while maintaining the stability criteria. The degree of polarization is above 99 percent. Through theuseofsingle-modefibers,thebeamqualityachievedamountstoM2 < 1.1.

Contact PersonDipl.-Phys. Oliver FitzauPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 26cE317


Optical System for the Independent Positioning of Multiple Laser Beams Where periodical structures are manufactured or large quantities of small parts have tobeprocessed,thethroughputcanbesignificantlyincreasedbyprocessingwithmultiple beams simultaneously. Most state-of-the-art multi-beam optics use static diffractiveopticalelements(DOEs)tocreatespotarrayswithhighefficiencyanduni-formity. However, distortion effects due to the principle of 2-dimensional laser scanner systems lead to a scan-angle dependent change of the spot array’s shape on the work piece. The topography of 3-dimensional surfaces can further distort the spot array. Frequently required positioning accuracies of < 10 µm for each beam within a spot array limit current systems to very small angles and plane surfaces.The spot position control unit (SPCU) presented here allows for the independent manipulation of the x-, y- and z-position of each beam within an exemplary 2 x 2 multi-beam optical system. The SPCU thus enables 2-dimensional scanning processes and 3-dimensional surface processing.

Contact PersonM. Sc. Oskar Hofmann Phone +49 241 [email protected] Aachen University – Lehrstuhl Technologie Optischer Systeme TOS

BOOTH 26dE317


Multiphysical Modelling of High-Power Diode Lasers Accurate modelling of state-of-the-art high-power diode lasers requires a description of their electrical, optical, thermal and mechanical properties and the complex interac-tions between them. Fraunhofer ILT’s Semiconductor Laser Simulation Software (SEMSIS) includes these effects to investigate the limiting factors regarding beam-quality as well asefficiencyandtooptimizetheepistructure.Thesoftwarecontainsadrift-diffusion-model describing the carrier injection, a microscopic gain model and a wide-angle beam propagation algorithm. Joule heating and nonradiative recombination are used as heat sources for the thermal model. Thermally and packaging induced strains can be calculated andinfluenceopticalgainandpolarization.Externalopticalsystems,e.g.forspectralstabilization, can be simulated using a Fourier-Optical approach or an interface to the raytracing software Zemax. A good agreement to measurement values was found. The software is currently being extended by a module describing the degradation of diode lasers aiming to identify and control critical parameters for their lifetime.

Contact PersonM. Sc. Martin AdamsPhone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 26aE317


Key Optical Components for Rugged Laser Systems

Many laser applications require a reliable long-term operation of the laser source in harsh environment. This means that the laser has to withstand temperature cycles and mechanical vibrations and shocks. This is especially true for industrial but also for space environment. With the goal to build a spaceborne LIDAR instrument that has to operate maintenance-free for more than three years a set of key optical components has been developed. In order to ensure long term stability especially when exposed to UV radiation, the key requirement is to avoid any organic material like adhesives or plastics. The soldering technique which is established for the mounting of laser diodes and laser crystals to heat sinks has been adapted for the mounting of mirrors, lenses, and nonlinear crystals for faraday isolators, pockels cells and frequency converters. Several thermal cycling tests between – 30 °C and + 50 °C as well as random vibration tests of 14 grms have been performed to validate the required robustness.

Contact PersonDr.-Ing. Heinrich Faidel Phone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

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2726

Coaxial Process Monitoring through f-Theta Lenses Process monitoring is a key factor in many laser material processes due to the demand for reliable and stable process conditions. When using on-axis process monitoring it is unavoidable to choose an observation wavelength different from the processing wave-length if one wants to observe the melt pool and not the laser spot itself. By choosing a different wavelength, lateral chromatic aberration occurs in not chromatically corrected optical systems with optical scanning units and f-Theta lenses. These aberrations lead to a truncated image of the process on the camera or the pyrometer, respectively. To tackle this problem, the scanner-based optical system is reproduced in a simulation environ-menttopredicttheoccurringlateralchromaticaberrations.Inaddition,aseconddeflect-ing system is integrated into the optical setup. A predictive control is developed that usestheadditionaldeflectingsystemtointroducereverselateraldeviationsinordertocompensate the lateral effect of chromatic aberration.

Contact PersonDipl.-Ing. Georg KönigPhone +49 241 [email protected] Aachen University – Lehrstuhl Technologie Optischer Systeme TOS

BOOTH 26gE317


Compact Laser Cutting Head with High-Power Optics Made of Synthetic Monocrystalline CVD Diamonds Highly dynamic cutting applications require compact machining heads for medium laser power in the kW range. Conventional optical materials such as quartz or optical glass have only limited suitability for these applications. Compared to established materials, monocrystalline synthetic CVD diamond has a variety of outstanding properties, such as high hardness, thermal conductivity, and a high refractive index. Since diamond has suchadvantageousthermalproperties,theopticscanbeefficientlycooledevenatverylarge power densities. The research presented here focused on reducing the size and weight of the cutting head by optimizing the mechanical and optical design. So that the installationspacecouldbeminimized,thefiberendisimagedontotheworkpiecewitha compact optical group instead of a conventional arrangement consisting of collimator and focusing unit. This cutting head is more than 90 percent lighter than conventional compactcuttingheads.Inthefirstapplicationtrials,astainlesssteelsheetwitha thicknessof1.5mmwascutwithdiamondopticsandasingle-mode1kWfiberlaser.

Contact PersonDipl.-Ing. Dipl.-Wirt.-Ing. Martin TraubPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 26hE317


Model-Based Assembly of Optical Systems The assembly of optical systems used e.g. in laser systems is commonly carried out by hand. For precision and economic reasons, automated solutions are required. Shown is an assembly cell using a model-based approach to assemble an individualized anamorphic telescope. This approach enables the assembly cell to determine an assembly sequence, to calibrate itself in conjunction with the optical model and then carry out a function oriented assembly process. The assembly process itself successively adjusts and mounts the individual lenses while optimizing the position and the optical system toward the highest optical functio-nalityduringeachassemblystep.Theapproachishighlyflexibletowarddifferentopticalsystems. By using a Multi-Agent-Based-System (MAS) as architecture for the controlling software, changing the hardware-setup, measurement system, optical system etc. enables a decentralized process control and, thus, takes minimal effort.

Contact PersonM. Sc. Martin HoltersPhone +49 241 [email protected] Aachen University – Lehrstuhl Technologie Optischer Systeme TOS

BOOTH 26eE317


Fiber Bragg Gratings for Frequency Stabilization of Diode Lasers We present a setup to write Fiber Bragg Gratings (FBG) using two-beam-interference and an ultrashort pulsed laser. For power scaling of diode lasers, DWDM with external opticalelementsforwavelength-feedbackarecommonlyused,beforethebeamisfinallycoupledintoanopticalfiberforthetransportationtotheapplication.Since FBG can be used to provide spectral feedback as well, they offer the possibility torealizefiberintegratedfrequencystabilization,hencesimplifyingtheexternalcavitysetup by at least one element. The modular setup of the presented workstation enables fastanflexibleinterchangeofthefocusopticsandthefiberholders.With6degreesoffreedom,thelinefocusandthefibercorecanbeadjustedco-linearlywithanaccuracyup to 1 µm and < 1 mrad.Using a written FBG (R = 7 percent, 1075 nm) the wavelength of a diode laser was successfully stabilized achieving a performance that is compoarable to a VBG setup.

Contact PersonM. Sc. Sarah KleinPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 26fE317



2928

Development of Ultrafast Lasers with Multi-kW Average Power Ultrafast lasers at 1 µm wavelength with higher and higher average output power are introduced to the market and get established for industrial applications. Yb:Innoslab amplifiersdevelopedatFraunhoferILTemergetoabenchmarkinthemulti-100Wclass.Yb:Innoslabamplifierswithaveragepowersupto1kWandpulsedurationsof ~1 ps are state of the art. To serve current and future demands of mass-production and to investigate new applications the Fraunhofer Forschungscluster Advanced Photon Sources has been established to further push the average power of ultrafast lasers up to 10 kW. To enable new appli-cations in production, metrology and science the pulse duration of these lasers is pushed toshorterpulsesatthesametime.Togetefficientintoapplications,theselaserswillbemade available in a new user facility to be erected in 2018/2019.On site the work on different ultrafast lasers of 20-1000 W can be inspected. An experimental setup for a versatile pulse-compression module is presented. Pulses of 1 ps duration are compressed to 100 fs at 10-100 µJ pulse energy and up to 5000 W average power.

Contact PersonDr. rer. nat. Peter Rußbüldt Phone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 27E318


New Approach in Seam Tracking by Texture-based Image Processing When the shipbuilding and vehicle construction sectors weld components from sheet metal, they must be able to reliably identify the joint geometry and position with an automatic image processing system. In contrast to classical approaches based on brightness gradients, an alternative approach has been pursued by Fraunhofer ILT here: Segmenting the image data based on textures, whereby changes in the texture of adjacent image details are used for their differentiation and delineation. In this texture-based analysis,theimageinformationisclassifiedbymeansofafilterbankandcomplexstatisticalalgorithms. Because of the computing power required for this, real-time implementation has hitherto been uneconomical. The performance of FPGA as well as PC hardware, however, has been improving constantly. Nowadays such advances make it possible to economically implement the image processing algorithms. The system has an image sensor arranged coaxially in the beam path of the welding head. By means of real-time image processing, it measures the distance between the joint and the interaction point as well as the joint width for an adaptive control.

Contact PersonM. Sc. SFI (IWE) Wolfgang Fiedler Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 28aE327

SYSTEM TECHNOLOGY

Dense Wavelength Combining and 35 µm Fiber Coupling of High-Power Laser Diodes We present a prototype module for dense wavelength combining in the medium powerrangeandcouplingintoafiberwith35µmandanumericalapertureof0.2. The approach is based on DFB diode laser bars with a wavelength spacing of 2.5 nm andultra-steepdielectricedgefilters.Theradiationofadiodelaserbar,inwhicheachsingle emitter is stabilized at chip level on its own wavelength, was super-posed for the firsttime.Todate,anoutputpowerof46Whasbeenachievedfromafiberwith35µmcorediameter.Inthispowerrangesignificantlymorecompactandrobustsystems can be constructed through the use of internally stabilized diode laser at lower costs. For further power scaling, the losses incurred are reduced by optimizing the diode lasers, optical design and assembly. In addition, a polarization coupling is integrated into the setup.

Contact PersonDipl.-Ing. Dipl.-Wirt.-Ing. Martin TraubPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 26iE317


LIDAR System for Applications in the Automotive Industry In vehicle technology, driver assistance systems are increasingly being used to partiallyor fully automatically drive the vehicle. Such systems must be able to detect surroundingobjects both quickly and reliably. In addition to radar sensors, LIDAR systems are increas-ingly being used for such purposes. These systems determine distances to objects bytime-of-flightmeasurementsofreflectedlaserradiation.ConventionalLIDARsystemsincorporateamechanicalbeamdeflector(rotatingscanner),whosefunction,samplingrate and reliability may be affected by the vibrations that occur in the vehicle. For thesereasons, a LIDAR system without moving parts is desirable, one that operates reliably,maintenance-free, at a high sampling rate, in a large ambient temperature range andunder mechanical loads due to shocks and vibrations. For this purpose, a LIDAR demons-tratorwithalinearbeamprofilewithoutmovingpartswasdevelopedatFraunhoferILTin close cooperation with Fraunhofer IMS in Duisburg.

Contact PersonDr. rer. nat. Thomas Westphalen Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 26jE317



3130

Support-Free Photo-Polymerization with “TwoCure” Much like stereolithography, 3D printing of plastic parts using photolithographic light exposure causes liquid resins to harden layer by layer. This additive process has one significantdisadvantagehowever:itrequiressupportstructuresthattheusermustincludein the design, then construct during the process, and then laboriously remove from the product. Similar to conventional systems, “TwoCure” uses an LED light unit that illumi-nates the liquid resin in the component’s layered geometry. Additionally a controlled thermal phase shift of the material is used to stabilize the 3D objects in volume (instead of support structures). The material is applied warm and then irreversibly cured by light. At the same time the cooled build space ensures that the 3D volume being created layer by layer freezes to form a solid block with the resin. The user can subsequently liquefy this at room temperature, so that the support material drains off: what remains are the 3Dprintedcomponentsthatjustneedtobebrieflycleanedandpost-cured.“TwoCure”enables photopolmyer 3D printing without support-structures.

Contact PersonDipl.-Chem. Holger Leonards Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 29E321


Surface Functionalization by VCSEL Technology Increasing demands for surface properties regarding wear protection, corrosion protection and low friction exceed the limits of current state of the art base materials. Hence,thinfilmsareappliedontothebasematerialtoensurereliableandenduringperformance. However, heating steps are often necessary to functionalize (dry, sinter, partiallymeltorcrystallize)theappliedthinfilms.Thereplacementofconventionalheating by laser treatment allows for reaching high temperatures in top layers com-bined with high temperature gradients, enabling the use of temperature sensitive base materials. Moreover, surface functionalization by VCSEL technology allows for dynamic adaptationoftheintensitydistributionprofilebasedonsinglecontrollableemitterrows.The intensity distribution and thus the temperature distribution in the workpiece can be adapted to the individual application. This leads to many possible applications in a wide fieldofdifferentmarkets.

Contact PersonJonas MertinPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 30aE313

SURFACE TREATMENT

System for Closed-Loop Control of Laser Spot Position on Seam Because of the growing demand from customers, who want different materials, diameters and wall thicknesses, and to beat off competition, manufacturers need to improvetheoverallefficiencyoftheirproductionandintroducenewmanufacturingtechniques to reduce product life-cycle costs.Fraunhofer ILT introduces a seam tracking system for monitoring during welding and the detection of seam position, direction as well as interaction point position. The seam tracking system consist of an integrated welding head equipped with high speed camera imaging a region that includes the tool centre point and a region offset in front of the tool centre point. The image is analysed online by digital image processing, in detail the seam found by line detection and tool centre point by comparison against a threshold. The seam tracking system is able to detect the position and orientation of the seam and toolcentrepointsimultaneously.Thisisasignificantadvantageoftheseamtrackingsystem since it can accommodate shift in laser spot position. Commercially available seam tracking systems lack this capability. The seam tracking system furthermore images an area just in front of the tool center point and visualizes to the operator. For reliable imaging during welding the area is illuminated with light in NIR spectrum.

Contact PersonM.Sc. SFI (IWE) Wolfgang Fiedler Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 28bE327

SYSTEM TECHNOLOGY

Process Monitoring of Welded FRP Tapes with IR Technology In order to improve the production of a laser welding process an online monitoring devicewasdeveloped.TodetecttheconsolidationqualityofweldedFRPlayersdefinedembossments were applied into the material surface. These embossments can be visualized with an IR camera in order to analyze the consolidation quality during the welding process. With a machine learning algorithm the visualized embossments can be found precisely and each embossment can be assigned to a consolidation quality. This way the online monitoring device save costs by avoiding unnecessary waste and replacing a follow-up inspection of the manufactured products. The shown set-up demonstrates a simulated welding process in which the already welded FRP tape is heated by a laser and measured during heating by using the machine learning algorithm from the online monitoring device.

Contact PersonM. Sc. Andrea Lanfermann Phone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 28cE327

SYSTEM TECHNOLOGY


3332

Laser Ribbon Bonding for Power Electronics Laserribbonbondingisanewfieldofapplicationforlasermicroweldingintheelec-tronics industry especially in the area of power electronics. Traditional ribbon bonding is conducted by using ultrasonic welding to create the bond between the aluminum or copper ribbon and a conductive surface. By developing a new laserbonder, equipped withafiberlaser,agalvanometricscanner,afocusshifterandabeamfocusinganddelivery system, a new technology for ribbon bonding is created. In addition, it is possible to integrate process monitoring into the optical system. Results will be displayed incuding aluminum and copper ribbon bonds with a thickness up to 500 µm to DCB-substrates or battery cells. For the laser welding of the ribbons spatial and temporal power modu-lation is being used and the effect of this approach on the welded ribbons is presented.

Contact PersonM. Sc. André HäuslerPhone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 31bE310

JOINING

LaserTAB: More Efficient and Precise Electrical Contacts Thanks to Human-Robot Collaboration Laser-Based Tape-Automated Bonding (LaserTAB) relies on a clever combination of robotics and a laser scanner with new optics as well as a self-developed process moni-toring. Attached to the optical system is a spacer ensuring that the optics complies with the distance (focal length) required for the process. This way the LBR iiwa “feels” when the spacer touches the weld and starts the welding process. Thus, the welding points are always held at a constant distance from the lens thanks to the spacer and the sen-sing robot. In detail, we will show concrete applications to demonstrate how the micro joining process in battery technology can be made more precise and reliable with the help of this lightweight robot. Apart from prismatic cells we will also show applications with round and pouch cells. In a demonstration we also combine the two processes of micro joining and 3D printing, in which this welding process plays a leading technical role.

Contact PersonM. Sc. Johanna HelmPhone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 31cE310

JOINING

Laser-Based Production of Embedded Sensors With the establishment of the Internet of Things, the networking of smart objects, a new sensor era has begun: a diversity of functional sensors plays a part in industrial and daily life objects. Whether for antennas and temperature sensors in the food industry or for strain gauges or body sound sensors regarding the component monitoring, the trend is towards printed sensors directly onto the part to be monitored at very low-cost. Using electric and dielectric inks and pastes in a digital printing process, laser-based post treatmentallowsforrapidandenergyefficientcreationofsensorsandconductingpathsonto components. This booth shows demonstrators of printed and laser funtionalized strain sensors. Live measurements with alternating loads are demonstrated showing its compatibilitytostandardamplifiersandcommercialequipment.

Contact PersonM. Sc. Matthias Rehberger Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 30bE313


Laser Impulse Metal Bonding (LIMBO®) For the integration of high power electronic components in conventionally low voltage environments, e.g. busbar system in cars, the joining of massive copper interconnec-torsonthermallysensitivesubstrates(e.g.PCBs,DCBs)posesasignificantkeyelement.However, the requirements of power electronic components represent a challenge for conventional interconnection processes due to the required high temperature stability and high reliability of the joint. The approach “Laser Impulse Metal Bonding” (LIMBO®) enables to melt a 0.2 mm copper connector over a gap to a PCB, whereas the melt is accelerated by temporal modulation of the laser beam towards the PCB metallization. This enables a minimal energy deposition in the PCB and achieves a weld penetration depth of less than 20 µm in the metallization while creating a joint with a crosssection of Ø 200 µm.

Contact PersonM. Sc. Woo-Sik ChungPhone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 31aE310

JOINING


34


35

Cladding Head with Coaxial Wire Feeding for Laser Metal Deposition (LMD) For some materials and parts it is advantageous to use wire instead of powder additives for the LMD process. By utilizing a wire as feed material, major disadvantages of currently used powder-based LMD processes can be eliminated. Contamination of the process cellwithmetalpowder,significantmateriallossesduringtheprocessandinsufficientpowder quality are just some of the problems which are solved by this approach. A continuous circular laser beam is one of the distinguishing features of this new laser cladding head. The laser beam and the wire are arranged coaxially to one another. Through this design the welding process is truly independent of the direction of feed. A very high degree of material utilization paired with a welding process completely independentfromthefeeddirectionoftheprocessresultsinefficientandprecisebuildup of two- and three-dimensional geometries. Reduced mass of the head through advanced design makes highly dynamic cladding processes feasible. By allowing the useoffinefeedwires,evenintricategeometriescanbebuiltupinnear-net-shape.Allopticalelementsofthecladdingheadarereflectivesoitispossibletousevarioustypes of lasers.

Contact PersonM. Sc. Jana Kelbassa Phone +49 241 8906-8331 [email protected] Fraunhofer-Institut für Lasertechnik ILT


Photonic Sources and Components for Quantum Technologies QuantumTechnologyisquiteanewfieldofphysicsandengineeringwithanenormousapplicationpotential.Afirstgenerationofapplicationslikelasers,semiconductorsandatomicclockshavenotonlyfoundtheirwayintoindustrialuse,butsignificantlychangedour daily life. Now a second technology generation is emerging, including applications in quantum computing, quantum communication and quantum sensing. These applications are based on quantum mechanical effects like superposition or entanglement and require sophisticated, highly-integrated, stable and low noise photonic sources and components for their robust technical implementation. Here, Fraunhofer ILT makes us of its photonic system know-how to develop solutions for the generation, manipulation and conversion of photonic quantum states as well as for the integration of such systems based on wave-guide technologies. The Fraunhofer Lighthouse Project QUILT addresses quantum imaging applications based on frequency-shifted entangled photon pairs, allowing imaging and spectroscopy in interesting spectral regions while detecting in the visible.

Contact PersonM. Sc. Florian ElsenPhone +49 241 [email protected] für Lasertechnik ILT


Absorber-Free Laser Welding Of Transparent Polymers Over the past few years, an increase in product quality requirements and the trend towards miniaturisation of plastic products from the automotive, electronics and medical technology sector could be observed. This leads to an increase in the demands on the production and joining processes. Laser-based joining processes offer the advantage of enabling non-contact energy input as well as low mechanical stress on the joining partners. While in the past, the use of absorbers such as carbon black was necessary due to the transparency of most polymers in the wavelength range of classic beam sources (λ = 800 - 1100 nm), it is nowadays possible to join transparent polymers without the use of absorbers. For this purpose, novel radiation sources are used which emit radiation in the area of the polymeric intrinsic absorption bands (λ = 1500 - 2000 nm).

Contact PersonM. Sc. M. Sc. Phong NguyenPhone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

JOINING

Joining of Fiber Reinforced Plastics (FRP) and Metal Lightweight construction is a central issue in automotive and aerospace industry due to the need to reduce CO2 emissions. One way to achieve weight reduction is to use different materials adapted to functions and local loads. New paths for weight optimi-zationareespeciallyenabledbythecombinationoffiberreinforcedplasticsandmetals.These hybrid components combine their unique characteristics and thus can lead to advantageous construction parts properties. As a result, light and at the same time rigid components are realized. The need for joining these dissimilar materials without using additional materials like adhesives or primers is the central challenge. An approach to overcome the problems of state-of-the-art technologies is using laser radiation with high-speed, polygon-based scanning systems to ablate the metal surface in order to create microstructures with undercut grooves. By melting the above placed plastic with laser radiation, the material expands into these structures and forms after setting a joint based on mechanical interlocking.

Contact PersonDipl.-Wirt.-Ing. Christoph Engelmann Phone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 33E302

BOOTH 34aE316

BOOTH 31dE310

BOOTH 32E304

JOINING



3736

Application of Adapted Powder Nozzles to Areas of Limited Access by Laser Metal Deposition (LMD) Highly loaded areas on components are exposed to corrosion and wear leading to a reduced life time or failing of the component. An approach to enhance the components performance is to reinforce the area with a resistant coating by Laser Material Deposition (LMD) with metal powder. The same technology can be applied for adding 3D structures to components in hybrid additive manufacturing. In both cases the limited accessibility of the powder nozzles can inhibit a successful implementation.The recent development of a novel coaxial powder nozzle concept will be presented allowingtheadaptionofthenozzletipshapetothespecificapplication.Theabilitytodesignnarrowtipsallowsaccesstosectionswhicharedifficulttoreachlikegrooves,notches, inner edges or cavities and by this expands the range of applications. A further advantageistheexchangeabilityofthenozzletipswhichresultsinaflexibleandcosteffective cladding solution.

Contact PersonDipl.-Ing. Gerhard Backes Phone +49 241 [email protected] für Lasertechnik ILT


Lasers and Frequency Converters with Customized Wavelengths from UV to MIR Convertinglaserradiationtonewapplication-specificwavelengthsincreasesthepossi-bilitiesofusingmodernsolid-state,fiberanddiodelasersinindustryandresearch.By tailoring the combination of fundamental laser source and frequency converter, the FraunhoferILTdevelopsefficientandcost-optimizedbeamsourcesforawidevarietyofapplications. The output parameters of our customized lasers and frequency converters can provide laser wavelengths from UV to MIR, output power from the Milliwatt-level up to multi-hundred Watts and all time-regimes from CW operation to ultrafast pulses. Exhibitsincludecompactpackagesofefficientfrequencyconvertersaswellasexemplaryovendesignsfornonlinearcrystalsandtunablelasercrystals.Highlightsarefirstly,anOPG-based converter box providing high-power short pulses with addressable wave-lengths in the IR and secondly, a robust OPO unit with soldered optics and crystals for satellite-based LIDAR measurement of Methane.

Contact PersonDr. rer. nat. Bernd JungbluthPhone +49 241 [email protected] für Lasertechnik ILT


GENERATIVE METHODS

BOOTH 35E100.A04

BOOTH 36E100.A05

BOOTH 34bE316

BOOTH 34cE316

Robotic Systems in Additive Manufacturing with Laser Material Deposition (LMD) When using Laser Material Deposition (LMD) for Additive Manufacturing (AM), industrial robots can offer unique advantages. Beyond the potential for cost-saving, the kinematic configurationsallowhighversatilityandflexibilityinmanyapplications.Whileprogram-ming such systems with 6 and more axes can be challenging, adapted CAM solutions fromFraunhoferILToffereaseofuseandspecificfeaturesforefficientAMapplications.In combination with additional innovations such as adaptive beam shaping optics, highly efficientpowdernozzlesandfastpowderswitching,roboticsystemsforAMwithLMDare now a feasible option for many applications. Potential drawbacks such as reduced path precision compared to cartesian systems are also being evaluated at Fraunhofer ILT, permittingapplication-specificevaluationofthesuitabilityofdifferentkinematicsystems.Examples of components manufactured fully by LMD as well as by Hybrid-Additive Manufacturing are shown.

Contact PersonM. Sc. Jan BremerPhone +49 241 [email protected] für Lasertechnik ILT

Direct Generation of Laser Radiation in MIR As part of the project “DIVESPOT” with the Max Planck Institute for Structure and DynamicsofMatter,FraunhoferILTinvestigatedthedirectgenerationandamplificationof laser pulses in the MIR range at 2.6 to 3 µm output wavelength and with pulse dura-tions between 100 ps and 1,000 ps. It addition, the institutes examined gain media that can address the wavelength range without nonlinear processes. Their goal is to develop a new precision tool for surgery. For generating laser light at a wavelength in the range of 3 µm, the chromium-doped II-VI compound semiconductor material zinc selenide was used as gain media. The pump source is a thulium solid-state laser emitting at a wavelength of 1.9 µm, which can be operated both continuously and pulsed with pulse durations of a few hundred nano-seconds. This laser was used to optically pump another resonator with Cr: ZnSe gain media. This laser then emits laser radiation in the wavelength range between 2.6 to 3 µm. The output wavelength can be tuned by selective elements in the resonator.

Contact PersonM. Sc. Benjamin Erben Phone +49 241 [email protected] für Lasertechnik ILT



3938

High-Speed Cutting and Welding High speed laser cutting is a key factor for the competitive use of lasers in sheet metalprocessingonhighperformingflatbedmachinesand–withincreasingimpor-tance – in laser blanking from coil. High speed cutting replacing mechanical blanking isattractivebecauseofit’sflexibility,leadingtosavingsinmaterialinput,toolsandfloorspaceaswellastoconstantquality,avoidingthedifficultiesinmechanicalcuttingofhigh strength steels. Steel sheets of 1 mm thickness can be cut at 100 m/min with 4 kW laser power and weld at 30 m/min with 2 kW laser power. For the process development Fraunhofer ILT operates a dynamic 2D machine with 5 g acceleration and 300 m/min maximumspeed.Thankstoafixedworkingheadandamovedworkpiece,themachineis predestined for versatile diagnostics both for high speed cutting and welding processes.

Contact PersonDipl.-Phys. Stoyan StoyanovPhone +49 241 [email protected] für Lasertechnik ILT

Artificial Intelligence Process Monitoring for Laser Welding Processes Machine learning and Big data analysis have shown their great strength in various fieldsofreal-worldapplications.Withrespecttoreal-timecognitivequalitydiagnosis,Fraunhofer ILT shows a multispectral, imaging and machine learning-based process monitoring system. This system has been integrated into processing optics and applied to a laser beam welding process showing an automotive production scenario. The cognitive architecture includes the areas of “Computer Vision” and “Machine Learning”. These methods are used to determine relevant features from the image data, such as the cooling rate of the component surface or the surface geometry of the melt pool. The calculation and evaluation of the characteristics requires considerable processor power and is accomplished for the real-time application with a Field Programmable Gate Array (FPGA). A training phase provides the basis for evaluating the process monitoring features. By means of the calculated process characteristics and expertly assessed weldingsamples,thecognitivesystemlearnstheclassificationofthecharacteristicsand, thus, how to recognize different process imperfections clearly.

Contact PersonM. Sc. Christian KnaakPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 38bE100.B06

CUTTING / JOINING

BOOTH 39aE100.B07

SYSTEM TECHNOLOGY

Local Laser Heat Treatment of Ultrahigh Strength Steel and Cold Rolled Blanks The use of ultra high strength steels in the automotive industry is increasing constantly due to their potential for weight reduction combined with improved performance. However, the high strength reduced ductility which is unfavourable for massive forming operation as well as for crash performance. Required is a material which locally provides ductility andstrength,accordingtomanufacturingoprationsand/orthefinalfunction.Awaytoachieve this is a local softening by laser heat treatment, either on the sheet or coil or on the part. High power lasers (> 10 kW) and temperature control enable the softening with highefficiencyandaccuracy.Sincelasersofteningisatoollessprocess,itishighlyflexible.Furthermore, different levels of softening can be adjusted, just as required for forming or performance. It can also be combined with other processes such as laser cutting. High-strength steels are mainly cut using lasers because die cutting leads to rapid wear of the die. Considering that the strength of new steels exceed the limit of 1500 MPa of steels in use towards 2000 MPa (e.g. MBW-K®1900) die cutting will even no longer be possible. However, laser cutting may lead to an undesired increase in hardness along the cut edge which can cause severe failure during a crash.

Contact PersonM. Sc. Rebar Hama-SalehPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 37E100.A06

SURFACE TREATMENT

Selective Laser Deposition of Conducting Paths on Electronic Devices Today conducting paths on electronic devices are typically galvanized or printed (e.g. via screenprinting)andsintered.However,thesetechnologieslimittheflexibilityregardinggeometry as well as thickness of the layers. A selective two-step laser coating process offers the potential to overcome these limitations and additionally provides a resource efficientprocesswithminimumwasteofthehighvalueadditives.Inafirststeptheconducting material (e.g. copper or precious metals) is deposited as paste with a dispenser on the substrate material. In a second step the layers are dried to evaporate solvent and other ingredients. Finally, the layers are remelted with a laser beam to form a dense and bonded layer on the substrate. The main challenges are the deposition of thin and homogeneous layers in the range of 20 - 50 µm and the bonding even to dissimilar substrates, e.g. ceramics.

Contact PersonDipl.-Ing. Dora MaischnerPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 38aE100.B06



4140

Laser Beam Welding of Ultrahigh Strength Dissimilar Welds The increasing demand for ultra-high strength steels in vehicle manufacturing leads to the application of new alloys. A stainless high manganese steel sheet with excellent strength and deformation properties stands in the centre of the development. Similar and dissimilar welds with a metastable austenitic steel and a hot formed martensitic stainless steel were performed. An investigation of the mixing effects on the local micro-structure and the hardness delivers the metallurgical features of a weld. Despite of carbon contents of up to 0.6 percent by weight none of the welds have shown cracks. Mechanical properties drawn from tensile tests deliver high breaking forces enabling a highstiffnessofthejoints.RecentlydevelopedalterationoftheSchaefflercurveconsider-ing the increased manganese content in the weld metal are proven to be powerful tools in understanding the complex metallurgy of the alloys produced during welding. Thus, a baseline for an effective and functional design of light-weight multi-material compo-nents is laid out.

Contact PersonDipl.-Ing. Martin DahmenPhone +49 241 [email protected] für Lasertechnik ILT

Welding of LMD-Produced 2.4682 and Wrought 2.4630 Dissimilar Joints Dissimilar welding of two high-temperature material, a shape welded Stellite 31 produced by laser metal deposition (LMD) and a wrought Nimonic 75 was performed. Emphasis was put onto the effect of the anisotropy of the LMD part on the weld quality. Tensile tests at room temperature show a dependency of fracture location and mode of failure on the load direction with respect to the layer orientation. The tensile strength of the welded joints amounts to 800 MPa and more. Yield strength ranges from 470 to 580 MPa. Fracture strains range from 8.3 to 14.3 percent depending on orientation and heat treatment. Fracture occurs in the majority of cases in the Stellite 31 base material of at the respective fusion line. The fracture shows a mixed mixed interdendritic cracking. At 750 °C all specimens broke in Nimonic 75 in ductile fracture mode. Strength measured supersedes the values of the either base materials. In general the welding suitability of this special dissimilar joint, in both cast and laser shape welded condition, was de-monstrated.


Issues in Welding Ultrahigh Strong Dual Phase Steels

Dual phase steels with ferritic-martensitic microstructure are an economic alternative to other high strength steels with respect to weldability and formability. When it comes to the application of grades above 800 MPa tensile strength a number of disadvantageous effects are induced by the welding heat. With increasing carbon equivalent an embrittle-ment of the heat-affected zone near the fusion line may occur. Especially when welded to ferritic material intermixing effects may cause the generation of material leaving ferritic islands in the weld which pose a notch due to their reduced hardness. Weakening and inhomogeneous structure leads to limitations in formability. Even at low deep-drawing ratioscrackingoftheweldoccurs.Duringflangingofthematerialundergoesacomplexsequenceofloadsresultinginanupsettingofthesoftenedheat-affectedzoneandfinallycracking because of exceeding forming limit and strength of the material. Based on a failure analysis from real life the chain of cause and effect above mentioned is developed withtheaimtodefineandtesteffectivemethodsforavoidingprematurecrackingand, as a consequence, to enhance the scope of utilisation of ultra-high strength dual phase steels in manufacturing.


BOOTH 39bE100.B07

JOINING

BOOTH 39cE100.B07

JOINING

BOOTH 39dE100.B07

JOINING

BOOTH 40E100.A07

MICRO TECHNOLOGY

Glass Frit Sealing by Laser Radiation

In industrial manufacturing glass solders are mainly applied in electro technology and electronics especially for the closure of electrode feedthrough and housing. The durability and the mechanical load of a glass solder joint depends on the mechanical stresses. Because of the problems with mechanical stresses the most joining processes requireatemperature-time-profilewhichcausesathermalimpactforthewholecompo-nentry. Often the required temperature sequence damages sensible components inside the housing by diffusion processes. Thus a soldering technology which works with reduced temperature input and a local heating is needed. Glass soldering by laser radiation is an alternative to reduce the thermal input because of the localised energy absorption. The absorption of the laser radiation by the glass solder is an essential condition for a successful soldering process. By absorption the laser radiation the necessary temperature for a constant heating, melting and crack free soldering is achieved.

Contact PersonDipl.-Ing. Heidrun KindPhone +49 241 [email protected] für Lasertechnik ILT


4342

High-Precision Ultrashort Pulsed Laser Micro Structuring by Means of Multibeam Processing Inthefieldofmicrostructuringwithultrashortpulsed(USP)laserradiation,multibeamprocessing is one approach to increase productivity and throughput. Compared to single-beam laser processing, the multibeam approach is based on the use of a diffrac-tive optical element (DOE) for massive parallel processing with multiple beams. In this way, high pulse energies can be applied whereby at the same time the surface quality of a typical USP laser process can be maintained. Surface structuring of stainless steel using a rectangular array with more than 100 beamlets generating periodic features for molding applications is presented. Applications for the demonstrated process include the functional or design structures for the automotive industry, consumer electronics orfiltrationtechnology.

Contact PersonM. Sc. Thilo Barthels Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 42aU102.1

MICRO TECHNOLOGY

Helical Drilling of Three-Dimensional Shaped Holes Using Ultrashort Laser Pulses Three-dimensional conical converging-diverging nozzle typically a de Laval nozzle can beusedformicropropulsionofmicrosatellites.Theprofilecontrol,surfaceroughnessand symmetry of the nozzle are key parameters to adjust its performance. The drilling of three-dimensional conical converging-diverging holes using helical drilling optics and ultrashort laser pulses is demonstrated. The helical optics enables the dynamically control oftheprofileofaholebyadaptingthehelicalpathduringthedrillingprocess.Ahalfangle up to 7.5° on the converging part and 5.7° on the diverging part are achievable in 0.5 mm and 1 mm thick stainless steel by means of classic helical drilling. By intro-ducingadynamichelicalprocess,thehalfangleofconvergingpartwithstraightprofilecan be extended to more than 45°. Moreover, the application of ultrashort pulsed laser radiation leads to high quality surface on the side walls with an average roughness of less than 1 µm.

Contact PersonM. Eng. Chao He Phone +49 241 [email protected] für Lasertechnik ILT

BOOTH 42bU102.1

DRILLING

Manufacturing of Glass Optics by Laser Ablation and Laser Polishing The current state of the development of a laser based process chain for manufacturing fused silica optics is presented. This process chain is currently under development and focuses on the fabrication of highly individualized, non-spherical optics, since con-ventional manufacturing methods tend to be comparatively slow and expensive in this field.Inafirststepfusedsilicaisablatedwithlaserradiationtoproducethegeometryof the optics. A subsequent laser polishing step reduces the surface roughness and a third step uses micro ablation to remove the last remaining redundant material. Laser polishing reduces the roughness down to Sa 1 nm. The micro-roughness is therefore alreadysuitableforopticsbutthewavinessandformaccuracyisstillinsufficient.Therefore an ultra-precision laser ablation process, the Laser Beam Figuring LBF, is under development. Ablation depths down to 5 nm are possible with a spatial resolution of < 100 µm.

Contact PersonDr. Christian Weingarten Phone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 41aU120.1

SURFACE TREATMENT

Laser Polishing of Metals The latest results on laser polishing of metals will be shown:• Machine tool for laser polishing• CAM-NC data chain for easy programming of the polishing of complex shaped 3D parts• Simultaneous and synchronized movement of 5 mechanical axes and 3 scanner axes together with a measuring probe for easy work piece alignement• Additive manufactured SLM parts polished with lasers• 2-gloss-effects on tools• Further laser polished samples (e.g. Titanium, Inconel 718, Aluminium, Tool steel 1.2343, GGG40, …)

Contact PersonDr.-Ing. Edgar Willenborg Phone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 41bU120.1

SURFACE TREATMENT


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Additive Manufacturing of a Guide Vane Cluster – Product Development Leads to Series Production Readiness Since it has a large amount of geometric freedom, the additive manufacturing process Laser-Powder Bed Fusion (L-PBF) has great potential for use in the production of small to medium lot sizes for the turbomachinery sector. Together with the project partner MANDiesel&Turbo,FraunhoferILThasidentifiedaguidevaneclusterofagasturbine:L-PBF increases the part functionality and reduces the production costs at the same time. To date, the guide vanes have been milled as twin segments from a solid block. L-PBF, however, makes it possible to manufacture them as a cluster consisting of 12 twin segments. Under design and manufacturing aspects, MAN and Fraunhofer ILT jointly developed the component for additive manufacturing with L-PBF. This work leads to the approval of the L-PBF manufactured guide vane cluster for series production.

Contact PersonDipl.-Ing. Anders Such Phone +49 241 [email protected] Fraunhofer-Institut für Lasertechnik ILT

BOOTH 44aDPP E.01.2


Aachen Center for 3D Printing – Powder Bed Fusion of XL Components The Aachen Center for 3D Printing, a collaborating Additive Manufacturing group formed by the Fraunhofer ILT and the Aachen University of Applied Sciences (FH Aachen), has been founded to offer primarily small and middle sized companies access to AM technologies. In 2017 the research group started the project SLM XL with the aim to develop the Laser-Powderbed Fusion (L-PBF) Fusion process to manuafactuire large components (> 250 x 250 x 250 mm³) according to the quality requirements. The research focus contains the entire SLM process chain for large components (data preparation, SLM process and post-processing of the components). In 2018, the research group will be part of the public funded project LEIMOT. In this project the L-PBF technology will be used to develop the next generation of automotive engines.

Contact PersonDr.-Ing. Dipl.-Wirt.-Ing. Sebastian Bremen | Prof. Dr.-Ing. Andreas Gebhardt Phone +49 241 8906-537 | +49 241 6009 [email protected] | [email protected] für Lasertechnik ILT / Kooperation 3D Druck FH

BOOTH 44bDPP E.01.2


Roll-to-Roll Laser Patterning and Simultaneous Encapsulation Organic electronics is promising to be one of the groundbreaking technologies to revo-lutionize our everyday lives by including new functionalities into nearly any item. Cost isthemostsignificantbarrier,sincenewfunctionalitiesshouldnotincreasetheprice of the product dramatically. Roll-to-roll production is the solution to overcome the price barrier. In combination with integrated laser processes new possibilities are opened up forcost-efficient,versatileandhighthroughputmanufacturinglines.Laserpatterning–the selective removal of layers without affecting the surrounding material – plays a key roleinestablishingthinfilmtechnologiesinproduction.Furthermore,theencapsulationof organic electronics is crucial for a reliable operation of these components. By appling diodelaserweldingprocesses,ageometricallyflexibleweldingseamcanbeachievedthat guarantees an impermeable sealing during roll to roll production. The exhibit shows amodularlabsystemforroll-to-rollfilmprinting,drying,laserpatterningandlaser encapsulation.

Contact PersonM. Sc. Ludwig Pongratz | M. Sc. Maximilian Brosda Phone +49 241 8906-8044 / [email protected] | [email protected] für Lasertechnik ILT

BOOTH 42cU102.1

MICRO TECHNOLOGY

Processing Transparent Dielectrics with Ultrashort Pulsed Laser Radiation In the recent years the demand of processing of transparent dielectrics like technical glasses, sapphire or ceramics has grown for industrial application. Due to its ability of high intensities and precise energy deposition ultrashort pulsed (USP) laser radiation isapromisingmethodtorealizecost-efficientprocessesinamaterial-savingmannerfor these class of materials.Current challenges for USP cutting processes are the improvement of edge quality and curvature. Furthermore, the induced stresses should be reduced to minimize crack formation. As part of the Digital Photonic Production (DPP) Research Campus, funded by the Federal Ministry of Education and Research (BMBF), 4Jet microtech, Amphos, Edgewave, Pulsar and the RWTH Aachen University – Institute Nonlinear Dynamics of Laser Process-ing NLD as well as Laser Technology LLT these issues are investigated on a large scale (1x1m)flatbasemachiningarea.

Contact PersonM. Sc. Martin Kratz Phone +49 241 8906-581 /[email protected] Aachen University – Lehrstuhl für Lasertechnik LLT

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MICRO TECHNOLOGY


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Application Adapted Freeform Optics for Surface Treatment The high variety of requirements for materials in the widest range of applications demands increasingly complex materials and material combinations that are specially adapted to the application. Often the current production methods, especially in the fieldofthermaltreatment,cannolongerkeepupAtothespecializedmaterials.Com-pared to a furnace process, the laser already offers various advantages such as selective thermal treatment and inline capability, especially in near-surface areas of the workpiece. Nevertheless,therequirementsintermsofmachiningquality,efficiencyandcomponentgeometry cannot always be met using conventional intensity distributions such as top-hat or Gaussian distributions. The use of adapted intensity distributions by beam shaping methods such as the use of free-form optics makes it possible to adapt the thermal treatment to the application also with regard to the above mentioned aspects. Freeform opticsaredefinedasrefractiveorreflectivesurfacesthatdiffersignificantlyfromsphericaland aspherical geometries. Examples of applications are softening or hardening of steel aswellasthinfilmprocessing.

Contact PersonM. Sc. Susanne WollgartenPhone +49 241 [email protected] Aachen University – Lehrstuhl Technologie Optischer Systeme TOS

BOOTH 45bDPP E.02.1

SURFACE TREATMENT

BMW i8 Roadster With the all-new BMW i8 Roadster a component optimized for the SLM process is usedinaseries-productionvehicleforthefirsttimeever.InsidetheconvertibletopasuitableapplicationforSLMwasidentified.InitiallyaPA6GF30partwasinuse,buttheneedforgreaterstiffnesswasidentifiedinhighlydynamictesting.Thus,ametalcom-ponent had to be developed. In a comparison between aluminum SLM and magnesium die-castingtheadditiveprocessprovedtobemorecost-efficientforaquantityupto60,000 – thanks to the fact the part was optimized for manufacturability and designed to reach a maximum packing density within the print job. The resulting geometries shows 10-times the stiffness at 40 percent less weight compared to the initially tested injection molded part made of PA6 GF30.

Contact PersonDipl.-Ing. Maximilian Meixlsperger Phone +49 89 382 [email protected] Group Additive Manufacturing Center

BOOTH 46Marquee next to Research Campus DPP

SPECIAL EXHIBIT

Institute for Toolless Fabrication AsanaffiliatedinstituteoftheAachenUniversityofAppliedSciences,theInstituteforToollessFabricationworkscloselytogetherwiththeteachingandresearchfield»High-Performance Processes of Production Technology and Additive Manufacturing« and in particular with the GoetheLab of the University of Applied Sciences under the direction of Prof. Dr.-Ing. Andreas Gebhardt. The Institute for Toolless Fabrication supportsyouintheoptimizationanddesignoftheentireprocesschaininthefieldof additive manufacturing. Our spectrum ranges from customer-oriented research and development through practical training to individual consulting services. The mastery of all additive manufacturing processes and their prep aration and post-processing steps areamongourcorecompetencies.Weconsidereconomicaspects,qualificationrequire-ments as well as the potential expansion of infrastructure and accompany you from the design,overtheproductionuptothefinishedcomponent.

Contact PersonDr. Julia Kessler Phone +49 241 [email protected] für werkzeuglose Fertigung GmbH

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Tailored Molds and Optics ThecoreteamofInnolitehasbeenworkinginthefieldofadvanceddiamondmachiningand ultra-precision machine tool development for complex optics manufacturing for the past 15 years. Based on various projects and strong cooperation with our partners, like in the BMBF Digital Photonic Production Research Campus, we could build up furtherexperienceinthefieldoflasermirrorsandopticspolymerreplication.Wetrytosupport and serve our customers along the entire process chain for optics and especially polymeropticsproductiontoensureefficient,highqualityproductsandonlylittlelossesat transitions between optics design and production or mold making an replication. An earlystageinvolvementinopticalproductdevelopmentwillensureoptimizedefficiencyand reduced risk for your optics production. Our current customers consider our expe-rience in data handling, program generation and the realistic estimation of achievable tolerances as highly valuable next to our diamond machining capabilities.

Contact PersonDr.-Ing. Christian Wenzel Phone +49 241 [email protected] GmbH

BOOTH 45aDPP E.02.1

LASER COMPONENTS


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SOLID STATE AND DIODE LASERS

Beam-Shaping Strategies to Generate Adapted Spatial and Temporal Temperature Profiles in Laser Heat Treatment Laser heat treatment, i. e. the local heating of surfaces and layers by means of laser radiationtoinducematerialmodifications,isgraduallyreplacingconventionalmethodsforthermaltreatment.Oneprocessparameterthatstronglyinfluencestheperformanceof these techniques is the beam’s intensity distribution. Different intensity distributions leadtodifferenttemporalandspatialtemperatureprofilesinthematerialandthereforeresult in different shapes of the heat treated zones. To increase machining quality and processefficiency,adaptedintensitydistributionsthatinduceapreviouslydefinedspatialandtemporaltemperatureprofilearecalculated.Tothisend,aninverseheatconductionproblem is derived and solved numerically. The obtained intensity distributions, which can be very inhomogeneous, are then realized using specialized beam-shaping techniques such as free-form optics and VCSEL-arrays.

Contact PersonM. Sc. Annika Völl Phone +49 241 [email protected] Aachen University – Lehrstuhl Technologie Optischer Systeme TOS

BOOTH 48aDPP 1.03

VCSEL Sources for Industrial Thermal Processing Philips Photonics is presenting new laser sources based on VCSEL (Vertical Cavity Surface Emitting Laser) micro laser arrays. The robust and compact laser modules deliver directed large-area beams of infrared power and are easily integrated into industrial heating applications and production processes. Thelatestmemberofthemodulefamilyisintendedforfibercompositemanufacturing.Delivering more than 2 kW output power, it is extremely compact and typically equipped with a concentration optics for 25 mm tapes. Stacking of many laser modules is possible for high productivity applications with wide processing width. All laser modules are operated by an electronic driver system, enabling precise power control and fast switching. As a unique feature, individual emission zones of the sources can be controlled independently. Thereby dynamic programming of the spatial heating patternispossible,enablinganunprecedentedlevelofprocessflexibilityandcontrol.At our new application lab, various laser modules and a live application demonstration are shown.

Contact PersonDr. rer. nat. Günther DerraPhone +49 241 [email protected] Philips Photonics GmbH Aachen

BOOTH 48bDPP 1.03

The Missing Link: Aconity3D between Research and Industry As a developer of equipment for powder bed laser melting of metals, Aconity3D aims at the activation of the latest research results for the utilization of this technology in an industrial context. At this year’s “Laser Technology Live“ Aconity3D presents three of currentlyfourbasic,fully-configurablemachinetypes:AconityMINI,AconityMIDI,andAconityONE. Located at the Photonics Cluster our rentable systems allow for feasibility studies, primarily for qualifying new materials, for manufacturing of components for Aconity3D’s in-house production and, not at least, for the testing of new functions and features – always in a view to industrial applications. Focusing process safety and reli-ability Aconity3D’s newly developed key feature at the interface between research and industry is Process Monitoring based on sensor data that enable immediate adjustment of process parameters in the subsequent layer (Closed Control Feedback Loop). To learn more, come by and visit us.

Contact PersonDr. Yves-Christian Hagedorn Phone +49 2407 [email protected] Aconity 3D GmbH

BOOTH 47aDPP 1.01


Digital. Additive. Production. The newly established Chair for Digital Additive Production DAP at RWTH Aachen University located on the high-tech campus of the RWTH University is committed toresearchandeducationinthefieldofAdditiveManufacturing(AM)technologies,including processing of novel materials, Design for Additive Manufacturing (DfAM), supply chain, production and end-to-end software solutions. No matter if your organization is a SME or large-scale, multinational corporation:Our unique portfolio enables both profound technological as well as economical perspectives on implementing AM within your company. We make sure that you succeed in exploiting the full potential of this groundbreaking technology.Get in touch with our experts and tell us more about the AM challenges you are currently facing. DAP is your “One-Stop-Shop Additive Manufacturing“ and supports your company‘s AM journey as a trusted and experienced partner.

Contact PersonM. Eng. M. Sc. Stephan Ziegler Phone +49 241 [email protected] RWTH Aachen University – Digital Additive Production DAP

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DPP Direct SLM Turbine Joint Laboratory The Research Campus project “Digital Photonic Production (DPP) SLM Turbine”, part of the BMBF funding initiative “Research Campus – Public-Private Partnership for Inno-vation”, aims at interdisciplinary research on the topic of Laser Powder Bed Fusion (L-PBF) in turbomachinery applications. The project partners MTU Aeroengines, Siemens AG, Fraunhofer ILT and RWTH Aachen University DAP pool their human resources to establish L-PBF as new forward-looking manufacturing method for the turbomachinery industry. We invite you to visit our joint infrastructure. Our offer: Experience the future of development in the joint research lab with its state of the art L-PBF equipment includ-ing modern process monitoring. Exchange information face-to-face with the industry and institute on site and let them answer your questions. Feel the partnership the DPP projects are targeting at. Witness how DPP creates a vast and outstanding network with excellent solutions. Sense how DPP faces the upcoming challenges in a fast developing globalized market.

Contact PersonM. Sc. Robin DayPhone +49 241 [email protected] RWTH Aachen University – Digital Additive Production DAP

BOOTH 51aDPP 1.14


Thermo-Optical Modeling of Optics for L-PBF Laser-Powder Bed Fusion (L-PBF) of metal parts is frequently suffering from thermo-optical effects. Especially the contamination of the protective window by metal plume causes absorption of laser energy and, thus, heating of the window. Since L-PBF is a highly dynamic process, the thermally-induced focus shift changes dynamically. Thereby, the utilized scanning strategy mainly affects the transient focus shift. In the scope of the project “DPP Direct”, transient thermo-optical effects at L-PBF are simulated based onacouplingoffiniteelementanalysis(FEA)andray-tracing.Thereby,thetemperature- dependentrefractiveindexprofileandsurfacedeformationsaretakenintoaccount.Differentscanning strategies are compared with regards to the axial and lateral focus shift.

Contact PersonM. Sc. Tobias Bonhoff Phone +49 241 [email protected] Aachen University – Lehrstuhl Technologie Optischer Systeme TOS

BOOTH 51bDPP 1.14


3D In-Volume Microstructuring Fundamental Research Lab Ultrashort pulsed laser radiation enables the production of precise micro devices in transparent dielectrics. As part of the Research Campus “Digital Photonic Production”, the industry partners LightFab and TRUMPF as well as the cooperating institutes LLT, TOS and NLD from RWTH Aachen University examine the underlying process dynamics as key for an improvement of the quality of produced devices. They realized an ultrafast pump-probe system for analyzing the process dynamics during the 3D in-Volume micro struc-turing or surface ablation. The system includes processing dielectrics simultaneously by multiple beam spots or arbitrary spatial intensity distributions tailored by a spatial light modulator. Moreover, the pulse front tilt, its manipulation, and its impact on the process can be experimentally analyzed.

Contact PersonDipl.-Phys. Sebastian Nippgen Phone +49 241 [email protected] Aachen University - Lehrstuhl für Lasertechnik LLT

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MICRO TECHNOLOGY

LightFab 3D Printer for Precision Glass Devices TheLightFab3DPrinterisdesignedforhigh-speedmaterialmodificationwithextremeprecision in three dimensions. The processes that can be done with the machines are precisionablation,multiphoton-polymerizationandin-volumemodificationintransparentmaterials for waveguide writing, glass-glass welding, internal marking and Selective Laser-Induced Etching (SLE). The SLE process is subtractive 3D printing in transparent materials and enables largest design freedom with µm precision and high productivity, e.g.arbitraryinternalmicrochannelsystemsareproducedinflattransparentblanks.Applications for those structures range from simple precision through or blind holes forfilters,interposersorfiberopticalconnectorstonewtypesofnozzles,microfluidicalchips and MEMS devices with three-dimensional freedom in geometry. LightFab offers the production of parts with SLE technology. In this context, it is part of the Digital Photonic Production Research Campus to investigate transparent materials in more depth and to develop process chains for improved digital 3D production in joint research.

Contact PersonDipl.-Phys. Martin Hermans Phone +49 241 [email protected] GmbH

BOOTH 50DPP 1.16

MICRO TECHNOLOGY


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Development of Algorithm-based Lattice Structures in 3D Metal Printing Laser-Powder Bed Fusion (L-PBF) process is a metal-based additive manufacturing tech-nology which can nearly produce any complex geometries. This is motivating to design parts and components in a lightweight manner. One approach to accomplish this, is to incorporate lattice structures in the design phase. Although the L-PBF technology can produce complex parts, it carries some material and machine-dependent processability constraints such as allowed overhang angle and minimum achievable resolution. Moreover, it is desired to take the loading and boundary conditions of the part in the respective application into account while generating lattice structures. The objective is to generate high-performance algorithm-based lattice structures in real time. They ought to consider not only processability constraints and loading conditions, but also geometrical orientation of the part. This is being carried out in DPP²-project by DAP in collaboration with ModuleWorks, Exapt and Fraunhofer IPT.

Contact PersonM. Sc. M. Sc. Omid Zarei Phone +49 241 [email protected] RWTH Aachen University – Digital Additive Production DAP

BOOTH 52bDPP Atrium


Unified Programming Environment for Additive and Subtractive Manufacturing EXAPT develops high-tech solutions for the NC-production. These range from innovative strategies for tool lifecycle management, production data and tool data management to state-of-the art manufacturing planning environments. The big advantage of EXAPT system solutions lies in their structure. All single components and modules are built on top of the same database platform and are therefore combinable in a straightforward manner.Customer-specificprocesschainsincludingvariousproductiontechnologiescan thereby be addressed to allow for a fully digitalized production.Within the Digital Photonic Production Research Campus, EXAPT is involved in answering the question of how to create and parameterize additive and subtractive manufacturing operationswithinaunifiedprogrammingenvironment.Here,EXAPTprovidesitsknow-how and solutions in the area of NC programming as well as technology database development.

Contact PersonMichael KönigsPhone +49 241 [email protected] Systemtechnik GmbH

BOOTH 52cDPP Atrium


Micro-Powder Bed Fusion (µ-PBF) – Extremely High-Resolution for Small Scaled Applications In order to expand the capabilities of the L-PBF process, research projects at the FraunhoferILTledtoasignificantincreaseofthedetailresolutionandsurfacequality of small-scaled parts. Until today, materials which can be processed by the procedure called Micro-Powder Bed Fusion (µ-PBF) are stainless steel (316L), cobalt-chromium and nickel-titanium shape-memory alloys. The powder with particle sizes smaller than 10 µm is applied in layers of 10 µm and molten by a laser beam with a spot size of 25 µm. In addition, modulated laser radiation is used to produce very small melt pools. µ-PBF enables manufacturing parts in the sub-millimeter range with structure widths down to 35µmandasurfaceroughnessofRa=1,5µm.Apromisingapplicationbenefitingfromµ-PBFprocessingisseeninthefieldofmanufacturinghighlycomplexmicrostructureswith integrated functionality. Due to the extremely high detail resolution and surface quality,itisnowpossibletoefficientlyproducesmallcomplexparts,suchasatomizersnozzles, devices for medical application or individual jewelry.

Contact PersonM. Sc. Lukas MasselingPhone +49 241 [email protected] für Lasertechnik ILT

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Research Campus Digital Photonic Production (DPP) – Jointly Shaping the Future The Research Campus Digital Photonic Production (DPP) is part of the eponymous funding initiative “Research Campus – Public-Private Partnership for Innovation” of the Federal Ministry of Education and Research. Thanks to the Research Campus DPP, RWTH Aachen University, Fraunhofer-Gesellschaft and around 20 industry partners can establish a long-term and systematic cooperation under one roof that aims to concentrate the various resources for joint, complementary and application-oriented basic research.In cooperative partnership, Research Campus DPP explores new methods and basic physical effects in order to use light as a tool in future production:• “Digital” – integrated digital process-chains for laser-based production• “Photonic” – innovative optical systems and laser beam sources for the digital factory• “Production” – comprehend and optimize processes and establish them in future production using novel materialsWe are looking forward to your visit and invite you to exchange experiences with our DPP partners from research and industry.

Contact PersonDipl.-Phys. Christian HinkePhone +49 241 [email protected] Campus Digital Photonic Production

BOOTH 52aDPP Atrium

CENTRAL INFORMATION


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ACunity – Sino-German R&D Platform for Advanced Manufacturing ACunity GmbH is an innovative company hatched by Fraunhofer Institute for Laser Technology ILT in Aachen, Germany together with senior experts from China. Combining Chinese and German resources ACunity is offering R&D management, application consulting, system integration services, training as well as contract manufacturing for laser based material processing and advanced manufacturing technologies, to provide customer tailored solutions along the entire value chain. Situated in the Photonics ClusterofFraunhoferILT,itbenefitsfromthelocal,closenetworkaswellasthestate-of-the art infrastructure this location offers. As a bridge between China and Germany, ACunity is building a Sino-German R&D platform, joining forces to incubate high-end products, key technologies and follow-up services for customers worldwide.

Contact PersonM. Sc. Chen HongPhone +49 241 [email protected] GmbH

BOOTH 52fDPP Atrium


ACAM – Your Partner for Additive Manufacturing The ACAM Aachen Center for Additive Manufacturing is a joint venture created by the Fraunhofer ILT, the Fraunhofer IPT, the RWTH Aachen University, the Aachen University of Applied Science and Spin-off companies located in Aachen. The ACAM (Aachen Center for Additive Manufacturing) bundles and facilitates the access to the additive manufacturingexpertiseoftheleadingscientificandresearchinstitutionsontheRWTHAachen Campus for the industry. The ACAM covers a wide range of topics and mate-rials – from polymers to metals, from design, construction and processes all the way to business models related to new possibilities in additive manufacturing. Additionally, the ACAM provides opportunities for joint research and development, a sophisticated training and education program, as well as an online platform enabling industrial members to build business connections. Through this online platform, industrial members can also stay up to date with the latest ACAM activities and exchange practical knowledge. Join the ACAM Community! Become a member of the ACAM.

Contact PersonIngrid Bongiovanni Roll Phone +49 241 [email protected] ACAM Aachen Center for Additive Manufacturing GmbH

BOOTH 52gDPP Atrium


Fraunhofer Institute for Production Technology IPT at Research Campus DPP The Fraunhofer IPT combines long time knowledge and experience in all areas of production technology. Located in Aachen we offer clients and project partners special andimmediatelypracticalsolutionsforaconnected,adaptiveproductioninthefields of process technology, production machines, production quality and metrology, as well as technology management. We understand production not only in individual operations, but consider all production processes and the links between all the elements of the overall process in their entirety – from pre- and product development via production pre-paration and assembly to the manufacturing. Our activites within the research campus „DigitalPhotonicProduction“arefocusedonthefieldofprecisionglassmoldingandpressing of laser optics and on the development of the digital photonic process chain. The Fraunhofer IPT currently employs a staff of approximately 450, currently working on projects in 9000 m² facilities, 5000 m² of which are used as laboratories and machining workshops.

Contact PersonDr.-Ing. Olaf DambonPhone +49 241 [email protected] für Produktionstechnik IPT

BOOTH 52dDPP Atrium

SYSTEM TECHNOLOGY

SLM Solutions Group AG – DPP Direct: Series Production with SLM

Lübeck-based SLM Solutions Group AG is a leading provider of metal-based additive manufacturing technology. SLM Solutions focuses on the development, assembly and saleofmachinesandintegratedsystemsolutionsinthefieldofLaser-PowderBedFusion(L-PBF). SLM Solutions currently employs over 360 members of staff in Germany, the USA, Singapore, Russia, India and China. The products are utilized worldwide by custo-mers in particular from the aerospace, energy, healthcare and automotive industries. The company is part of the Digital Photonic Production Research Campus, an innovative form of long-term partnership between research and industry under one roof funded by the BMBF. Thespatialproximitytoresearchpartnersenablesanefficientworkingenvironmentformultilateralprojects.ThemainfieldofresearchisL-PBFforserialproduction.BymeansofprocessandbusinesscaseanalysismaincostdriversofL-PBFwillbeidentified.The results are then used to optimize the process chain of L-PBF.

Contact PersonDipl.-Ing. Birk HoppePhone +49 241 [email protected] SLM Solutions Group AG

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Published byFraunhofer-Institut für Lasertechnik ILTSteinbachstraße 1552074 Aachen, Germany

Phone +49 241 8906-0Fax +49 241 8906-121info@ilt.fraunhofer.dewww.ilt.fraunhofer.dewww.lasercongress.org

ContactMarketing & CommunicationsDipl.-Betrw. Silke Boehr Phone +49 241 8906-288Dipl.-Phys. Axel BauerPhone +49 241 8906-194

Design and ProductionDipl.-Des. Andrea Crollwww.andrea-croll.de

© Fraunhofer-Institut für Lasertechnik ILT, Aachen 2018

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