photonics: the discipline that is making manufacturing smart · • industry has given strong...
TRANSCRIPT
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Photonics: the discipline that is making manufacturing smart
Institute for Applied Laser, Photonics and Surface Technologies ALPS, Fiber Technology Laboratory
Dr. Valerio Romano, Professor for Photonics
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Overview
• Short information on "Photonics" MSE Master
• Some thoughts on "smartness"• Examples of devices that might be used to implement
smartness in laser based machines
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Introduction
• 2018: important year for photonics in Switzerland:• Industry has given strong signals of commitment towards
photonics as a key enabling technology ALSO in Switzerland• teaching (MSE Master is being prepared as a profile and will
start in 2020• profile description is ready; implementation in a course of study will
start in January 2019
• Manufacturing technologies impulse programme
• This workshop:• Thinking about how photonics impacts on manufacturing• How photonics can be implemented in industry by projects,
research and teaching• How to find a sustainable and effective implementation in
funding
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Info: MSE Master Profile Photonics
• Profile description is in course of formulation and verywell on track
• 6 of 7 UAS participating• Early 2019 the modules wil be formulated• The contents discussed (not objected by anybody) are:
• Photonics for machining and manufacturing• Optical measuring• Optoelectronics and Electrooptics• Photonic systems (including design and simulation)• Manufacturing for photonics
• Planned start in fall 2020 (inscriptions 2019)
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Photonics and noble prizes...
Schores AlfjorowHerbert Kroemer
Jack Kilby
Roy Jay Glauber
John Lewis Hall
Theodor Hänsch
Charles Kuen Kao
Willard Boyle
George Elwood Smith
Andre Geim
Konstantin Novoselov
Serge HarocheDavid Wineland
Isamu Akasaki
Hiroshi Amano
Shuji NakamuraArthur Ashkin
Gérard Mourou
Donna Strickland
2014
2018 Laserphysik
Manipulation von Quantensystemen
Blaue dioden
2009
opt. Glasfaser
„für die Erfindung des CCD-Sensors“
2010 Graphen
2012
2000Optoelektronik
Entwicklung des integrierten Schaltkreises
2005
optical coherence
opt. Spektroskopie, Frequenzkamm
2018
Tabelle1
2000Schores AlfjorowOptoelektronik
Herbert Kroemer
Jack KilbyEntwicklung des integrierten Schaltkreises
2005Roy Jay Glauberoptical coherence
John Lewis Hallopt. Spektroskopie, Frequenzkamm
Theodor Hänsch
2009Charles Kuen Kaoopt. Glasfaser
Willard Boyle„für die Erfindung des CCD-Sensors“
George Elwood Smith
2010Andre GeimGraphen
Konstantin Novoselov
2012Serge HarocheManipulation von Quantensystemen
David Wineland
2014Isamu AkasakiBlaue Dioden
Hiroshi Amano
Shuji Nakamura
2018Arthur AshkinLaserphysik
Gérard Mourou
Donna Strickland
2000Schores AlfjorowOptoelektronik
Herbert Kroemer
Jack KilbyEntwicklung des integrierten Schaltkreises
2005Roy Jay Glauberoptical coherence
John Lewis Hallopt. Spektroskopie, Frequenzkamm
Theodor Hänsch
2009Charles Kuen Kaoopt. Glasfaser
Willard Boyle„für die Erfindung des CCD-Sensors“
George Elwood Smith
2010Andre GeimGraphen
Konstantin Novoselov
2012Serge HarocheManipulation von Quantensystemen
David Wineland
2014Isamu AkasakiBlaue dioden
Hiroshi Amano
Shuji Nakamura
2018Arthur AshkinLaserphysik
Gérard Mourou
Donna Strickland
https://de.wikipedia.org/wiki/Schores_Iwanowitsch_Alfjorowhttps://de.wikipedia.org/wiki/Charles_Kuen_Kaohttps://de.wikipedia.org/wiki/Faseroptikhttps://de.wikipedia.org/wiki/Willard_Boylehttps://de.wikipedia.org/wiki/CCD-Sensorhttps://de.wikipedia.org/wiki/George_Elwood_Smithhttps://de.wikipedia.org/wiki/Andre_Geimhttps://de.wikipedia.org/wiki/Graphenhttps://de.wikipedia.org/wiki/Konstantin_Novoselovhttps://de.wikipedia.org/wiki/Serge_Harochehttps://de.wikipedia.org/wiki/David_Winelandhttps://de.wikipedia.org/wiki/Herbert_Kroemerhttps://de.wikipedia.org/wiki/Isamu_Akasakihttps://de.wikipedia.org/wiki/Leuchtdiodehttps://de.wikipedia.org/wiki/Hiroshi_Amanohttps://de.wikipedia.org/wiki/Shuji_Nakamurahttps://de.wikipedia.org/wiki/Arthur_Ashkinhttps://de.wikipedia.org/wiki/G%C3%A9rard_Mourouhttps://de.wikipedia.org/wiki/Donna_Stricklandhttps://de.wikipedia.org/wiki/Laserhttps://de.wikipedia.org/wiki/Schores_Iwanowitsch_Alfjorowhttps://de.wikipedia.org/wiki/Herbert_Kroemerhttps://de.wikipedia.org/wiki/Jack_Kilbyhttps://de.wikipedia.org/wiki/Jack_Kilbyhttps://de.wikipedia.org/wiki/Integrierter_Schaltkreishttps://de.wikipedia.org/wiki/Roy_Jay_Glauberhttps://de.wikipedia.org/wiki/Koh%C3%A4renz_(Physik)https://de.wikipedia.org/wiki/John_Lewis_Hallhttps://de.wikipedia.org/wiki/Frequenzkammhttps://de.wikipedia.org/wiki/Theodor_H%C3%A4nschhttps://de.wikipedia.org/wiki/Charles_Kuen_Kaohttps://de.wikipedia.org/wiki/Faseroptikhttps://de.wikipedia.org/wiki/Willard_Boylehttps://de.wikipedia.org/wiki/Integrierter_Schaltkreishttps://de.wikipedia.org/wiki/CCD-Sensorhttps://de.wikipedia.org/wiki/George_Elwood_Smithhttps://de.wikipedia.org/wiki/Andre_Geimhttps://de.wikipedia.org/wiki/Graphenhttps://de.wikipedia.org/wiki/Konstantin_Novoselovhttps://de.wikipedia.org/wiki/Serge_Harochehttps://de.wikipedia.org/wiki/David_Winelandhttps://de.wikipedia.org/wiki/Isamu_Akasakihttps://de.wikipedia.org/wiki/Hiroshi_Amanohttps://de.wikipedia.org/wiki/Shuji_Nakamurahttps://de.wikipedia.org/wiki/Roy_Jay_Glauberhttps://de.wikipedia.org/wiki/Arthur_Ashkinhttps://de.wikipedia.org/wiki/G%C3%A9rard_Mourouhttps://de.wikipedia.org/wiki/Donna_Stricklandhttps://de.wikipedia.org/wiki/Laserhttps://de.wikipedia.org/wiki/Koh%C3%A4renz_(Physik)https://de.wikipedia.org/wiki/John_Lewis_Hallhttps://de.wikipedia.org/wiki/Frequenzkammhttps://de.wikipedia.org/wiki/Theodor_H%C3%A4nsch
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Lasers in production: one tool – many applications
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Virtual factory
• Virtual factory• Task: create a factory to produce a symbolic object (Einstein)• Solution:
Data reshapingin our office
Artwork byRobley Browne
On «Bundesplatz»
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What does "smart" mean (for a machine or a process)?• Some people see spiritual aspects behind
intelligence and smartness...
• No philosophical discussion on intelligence here.
• There is no such thing as an "error-free" process• In a manufacturing process, "smart" might mean to make a process
"autonomous", versatile, error tolerant and self repairing. This involves:• Fast data collection, very fast data transmission, ultrafast data analysis and
feedback;• digital storage of the process status;• taking repairing measures• resuming the process
• So "smart" might mean "Being able to collect big amounts of data veryquickly, transferring and analysing them and giving feedback in real time".
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Powder characterisation
Determination of the heat conductivity of a powderby a laser probe beam.
Optical determination of the laser penetration depthas a function of densification and granulometryof a metallic powder.
Projektarbeit «Pulvercharakterisierung» (PA1) Christian Marti, FS 2016
A. Streek, HS Mittweida
Also possible from backscattered dataduring the process
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Example: Surface inspection of powder bedProject work «Visuelle Überwachung des SLM Prozesses» (PA1) Matthias Fontanellaz, FS 2016
Shadows from obliquely incident light
Schatten-Differenzbild Binarisiertes Bild zur Höhenberechnung
Performance Mapping of the complete SLM chamber with 50µm resolution Min. detection heigth: 300µm Höhe (limited by computer
capacity) Measurement uncertainty: 23µm
Detection of delamination
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Real-time 2D Quotient pyrometry for SLM process
• Temperatures can be measuredat wavelengths that are transmittedby the process optics
• 2D thermal maps in real-time
• High data rate needed
• Wireless?
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SLM real-time thermal process inspectionBachelor Thesis «Real-time Überwachung des SLM Prozesses» H. Hodak & A. Keller, FS 2016Master Project work (EVA) Marco Jordi, 2017
Y.S. Lee / W. Zhang, 2015
▶ Mapping of the temperature distribution in and around the melt pool during laserirradiation
▶ Detection of instabilities in the melt pool
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Multi-beam delivery through HC fibers
Cregan et al., Science 285, p. 1537, (1999) P.J. Roberts et al., Opt. Express 13, p. 236 (2005)
Photonic bandgap fibre• Ultralow loss
(~1 dB/km demonstrated)• ~100 nm transmission
window
Benabid et al., Science 298, p. 399, (2002)
Kagomé fibre• Higher loss
(~0.1-1 dB/m typical)• ~1000 nm transmission
window
Debord et al., Opt. Lett. 39 (21), p. 6245, (2014)
“Single-ring fibre”• Ease of fabrication• Simple structure to model• Losses and transmission
windows comparable to best kagomé fibres
Pryamikov et al., Opt. Express 19(2), p. 1441, (2011)
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Delivering laser radiation in a wide range of wavelengths (UV - NIR) pulselengths (CW - femtoseconds)
through the same fiber.
Using the same fiber for the diagnostic signal
New generation of hollow core fibers
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Potential benefits of "smartness" in laser based manufacturing
• Self-correcting processes• Product-adapted process parameters• High energy effectivness
SLS part produced in a collaboration between EPFL/IAP (Ø15mm) Ø15mm, 200 25µm layers
P = 1.4W, f=2kHz,v=40mm/s
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Continuous wave interaction:3 watts average power
Near infrared pulsed laser sintering : Experiments Slide 16
Higher quality at lower power...
Pulsed interaction2 watts average power
100 µm
1 mm1 mm
100 µm
1 mm
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Sintered with Nd:YAG,
195 mW average power (critical)
150 ps pulses, 80 MHz
Sintered with Nd:YAG,
275 mW average power
150 ps pulses, 80 MHz
Consolidation of nanopowder with ps-pulses
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Summary• In connection with laser based manufacturing "smart"
means not only optimizing processes themselves but also continuously monitoring them and generating feedbackin real-time
• Photonics offers a wide range of tools to do that and in connection with digital data methods it can do itintelligenty.
• Fast transmission and processing of BIG amounts of digital data is necessary to implement "smartness"
Thank you for your attention
Photonics: the discipline that is making �manufacturing smartOverviewIntroductionInfo: MSE Master Profile Photonics Photonics and noble prizes...Lasers in production: one tool – many applicationsVirtual factoryWhat does "smart" mean (for a machine or a process)?Powder characterisationExample: Surface inspection of powder bedReal-time 2D Quotient pyrometry for SLM processSLM real-time thermal process inspectionMulti-beam delivery through HC fibersNew generation of hollow core fibersPotential benefits of "smartness" in laser based manufacturingHigher quality at lower power...Consolidation of nanopowder with ps-pulsesFoliennummer 18