Mr. Mathieu Valentin Profile

Mathieu Valentin

at ALPhANOV

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Proceedings Article | 2 March 2020 Presentation + Paper

Upscaling laser polishing for large 3D surfaces

F. Husson, M. Valentin, K. Aouati, R. Kling

Proceedings Volume 11273, 1127304 (2020) https://doi.org/10.1117/12.2545758

KEYWORDS: Surface finishing, Polishing, Laser processing, Surface roughness, Fiber lasers, Continuous wave operation, 3D scanning, Argon

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Laser polishing (LP) is considered as one of the enabling technologies primed to replace time-consuming manual polishing operations. During laser polishing, a thin layer of material is melted as a result of laser irradiation. Since molten metal is characterized by the melt pool relocation capabilities, laser polishing results in a significant decrease of surface roughness. Experiments on flat stainless-steel metal plates with a 1200W fiber laser lead to a surface roughness as low as Sa = 320nm (90% roughness decrease) with a processing time of approximately 40s/cm².

The aim of this study is first to demonstrate the potential for the upscaling of process speed. Upscaling laws based on power density and energy density will be discussed. Experiments are carried out to assess the upscaling from 1200W to a 10kW fiber laser in order to improve processing time. We can expect to reach a processing time of 5s/cm², a diminution by 4 to 6 times comparing to the current process. Under appropriate process parameters, certain classes of metallic materials are suitable for LP and can reduce their average surface roughness by more than 90 %.

Proceedings Article | 6 March 2019 Presentation + Paper

Additive manufacturing by wire based laser metal deposition

M. Valentin, C. Arnaud, R. Kling

Proceedings Volume 10909, 109090L (2019) https://doi.org/10.1117/12.2510074

KEYWORDS: Metals, Aluminum, Additive manufacturing, Fiber lasers, Titanium, Semiconductor lasers, Laser applications, Aerospace engineering, Spatial light modulators, Laser sources

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Laser additive manufacturing with metals is gaining more and more attention, and represents a large market in industrial applications, specifically for the aerospace sector in the future. The increasing diversity of applications requires the continuous development of specific process implementations: For high metal deposition rates, developments have focused on arc technologies (Wire Arc Additive Manufacturing, WAAM), based on conventional welding techniques. For high definition 3D parts, the development of laser technologies allowed the implementation of layer-based metal solidification on powder beds known as Selective Laser Melting (SLM). These two processes have specific characteristics, such as high deposition rate with low accuracy for WAAM and low deposition rate with high accuracy for SLM. In this paper, we will present the interest of wire-based deposition technologies with lasers, often referred to as laser metals deposition by wire (LMD-W). This new approach presents the best compromise between high deposition rates and good accuracy which corresponds to the need of the aerospace industry to build “cubic meter sized” parts. It meets the requests in terms of mechanical resistance and process duration. The first tests of the present study are carried out on aluminum alloy. The results show a good aptitude of aluminum despite of a recognized difficulty to implement this alloy in additive manufacturing due to problems with process stability at the edge of the deposit, filling strategies, and many more. In the present paper we focus our developments on the deposition rate in order to realize large aeronautics components.

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