Concept Laser claims to have raised the stakes in terms of innovation at Euromold 2014. The centerpiece was its multilaser technology. Concept Laser is upgrading its models to improve performance. In addition, the new M2 cusing machine, a fully integrated laser melting system, features modern design and several innovations.

Presentation of the new M2 cusing
The new M2 cusing was brought out with a modern appearance. (The LaserCUSING® process creates mechanically and thermally stable metallic components with high precision. Depending on the application, it can be used with stainless and tool steels, aluminum and titanium alloys, nickel-based superalloys, cobalt-chromium alloys or precious metals such as gold or silver alloys. Finely pulverized metal is fused using a high-energy fiber laser. After cooling, the material solidifies. Component contour is achieved by directing the laser beam with a mirror deflection unit (scanner). Construction takes place layer by layer (with each layer measuring 15-100 microns) by lowering the bottom surface of the construction space, then applying and fusing more powder.)

 

In addition to its new look, the machine also has a fully integrated structure. There are no longer any external components for the laser and filter system. The machine is equipped with a new filter design with an increased surface area of 20 square meters. The new filter module has fixed tubing and is fully integrated into the system. Filer replacement frequency has been reduced, increasing overall throughput of the system. This enhancement is important when using the multilaser technology. With the increased formation of smoke particles, the new filter further enhances productivity.

“Significantly faster build rates demand safer filter replacement concepts. Every filter change must be quick and easy. We have incorporated the new enhanced filter technology with safety as our primary consideration,” said Dr. Florian Bechmann, Head of Development at Concept Laser. For instance, the M2 cusing is fitted as standard with a water-submersible filter to guarantee safety when changing the filter.

Series enhancement with multilaser technology
“Our product range is now enhanced with multilaser technology that directly affects the exposure time. Our experience has shown that build rates can be increased by up to 80%,” said Bechmann.
The multilaser technology will initially be incorporated into the medium size segment. A multilaser version of the new M2 cusing – called the M2 cusing Multilaser – is available right now. It’s available with 2 x 200 W lasers, or alternatively with 2 x 400 W lasers.

What’s more, multilaser technology is now in the largest machine, the X line 1000R. In addition, in the near future the X line 2000R will be available, and will be fitted with 2 x 1000 W lasers. The aim is to drive ever faster construction speeds required by users in the aerospace and automotive industries.

Segmented exposure strategy improves the performance characteristics of components.

In segmented exposure, the higher laser power produces a rough surface finish. “Our new systems technology implements the hull-core principle, which enables density and surface quality to be controlled independently,” said Bechmann. This means that segmented exposure has an influence on the outer parts of the component – including overhangs and high-density areas of components – in a targeted manner. “An optimized exposure strategy improves both the level of quality and build speeds.” The end result is that a component’s performance characteristics can be improved through the use of segmented exposure strategy.

 

Enhanced real-time monitoring of the construction process with the QMmeltpool 3D

“‘Inline process monitoring’ is one of Concept Laser’s strategic technology fields, and one which we are now expanding with the QMmeltpool 3D,” continued Bechmann: “If we can dynamically micro-analyse the construction process, the level of quality increases. Important key industries with their sophisticated applications have enabled us to develop this important innovative step.”

In a comparable manner to computed tomography (CT), the QMmeltpool 3D makes it possible to generate 3D data sets that corelate directly to the component and its structure. This corrolation allows local effects that arise during the construction of the component to be clearly identified and analyzed. The practical added value of this innovation is not just that it is an original way of providing real time quality assurance, but also that production builds can be optimized through iterative variation of the parameters. Support structures can be adapted, and above all, the construction of the component can be structured in a more efficient and production-friendly manner. And not least, real time monitoring opens new opportunities in the materials research field.

 

New materials for laser melting systems

Concept Laser’s development center has certified two new materials, both of which premiered in Frankfurt. For high-temperature applications, Inconel 625 is now available. This material is mainly intended for use in turbine construction where components are exposed to high thermal stress of up to 1000°C. The second material is the stainless steel, 17-4 PH. This material can be hardened and consequently made highly resistant to abrasion, wear and corrosion. These properties are attractive above all in relation to medical instruments. The certification of 17-4 PH stainless steel applies to the Mlab cusing R, M1cusing, and the M2 cusing series.

Concept Laser
www.concept-laser.de