The document discusses Laser Engineered Net Shaping (LENS), an additive manufacturing process that uses a high-power laser to fuse metal powder layers together to build up and repair metal parts. LENS is used in industries like aerospace, industrial manufacturing, biomedical, and electronics. It allows for the fabrication of complex parts out of materials like stainless steel, titanium alloys, and Inconel with properties similar to or better than conventionally processed materials. While LENS provides advantages like part repair ability and design freedom, it also has limitations such as rough surface finish and low dimensional accuracy that may require post-processing.
3. How It Works
Uses a high power laser to melt metal
powder that is deposited onto the table.
Metal is sprayed onto the focal point on the
laser where the metal becomes fused
together. An inert gas is used to shield the
metal from atmospheric gases. It uses a
layered approach to manufacture the
components.
4. LENS Diagram
Click here to read more about
Laser Engineered Net Shaping
and to also view a diagram.
6. Advantages of LENS
Can be used to repair parts as well as fabricate
new ones
Has a very good granular structure
Powder forming methods have few material
limitations
Doesn’t require secondary firing operations
The properties of the material are similar or
better than the properties of the natural
materials
7. Disadvantages of LENS
Some post processing involved
The part must be cut from the build
substrate
Has a rough surface finish, may require
machining or polishing
Current maximum wall angle is 18 degrees
Low dimensional accuracy
8. LENS Specs
The building area is usually contained within
a chamber both to isolate the process from
the ambient surroundings and to shield the
operators from possible exposure to fine
powders and the laser beam.
The laser power used varies greatly, from a
few hundred watts to 20KW or more,
depending on the particular material, feed-
rate and other parameters
9. LENS Initial Applications
Fabrication and repair of injection
molding tools
Fabrication of large titanium & other
exotic metal parts for aerospace
applications
10. LENS Capabilities
Ability to build fully dense shapes
Closed loop control of process for
accurate part fabrication
Ability to tailored deposition parameters
to feature size for speed, accuracy, and
property control
Composite and functionally graded
material deposition
11. LENS Capabilities cont..
Three- and four-axis systems for complex
part fabrication
Wide variety of materials that, at minimum,
include: stainless steel alloys (316, 304L,
309, 17-4), maraging steel (M300), nickel-
based superalloys (Inco designations 625,
600, 718, 690), tool steel alloys (H13),
titanium alloy (6Al-4V), and other specialty
materials
Mechanical properties similar or better than
traditional processing methods
12. Material Specs
Material type
Ultimate Strength
(ksi)
Yield Strength (ksi) Elongation % in one
inch
LENS 316 Stainless 115 72 50
316 SS Wrought
Stock
85 35 50
LENS Inconel 625 135 84 38
Inconel 625 Wrought
Stock
121 58 30
LENS Ti-6Al-4V 170 155 11
Ti-6Al-4V Wrought
Stock
130 120 10
13. In Process Picture (Sky Scraper)
Click here to view an in process picture.
14. In Process Picture #2
http://www.tms.org/pubs/journals/
JOM/9907/Hofmeister/Hofmeister-9907.html
Click on the link below to view more pictures and
read more about Investigating Solidification with
the Laser-Engineered Net Shaping (LENSTM)
Process.
15. In Process Picture #3 and
Produced Parts
Click this link and scroll down to view
more pictures of the process and products.
