Simulation – Laser Processes and Systems

Overview

Our range of services

Simulation and modeling tools can be used to optimize a large number of laser applications, or even to build them in the first place. In this area, Fraunhofer ILT develops solutions, among other things, for specific designs of optics and free-form surfaces, laser beam profiles or scanning strategies for manufacturing products with tailored quality.

The spectrum ranges from laser-based cutting and welding to drilling and structuring to additive laser manufacturing processes. Simulation aims to help better understand the processes involved, to increase productivity and quality, and reduce costs and resources. To reach such goals, the institute uses numerical tools and methods of model reduction or meta-modeling as well as multi-scale simulations, among others. The software solutions it has developed are suitable for process simulations when metals, semiconducting materials, glasses, ceramics and plastics are applied.

We focus on the reduction of models to the specific application, which allows their use as a link between machine and production environment. Within the context of the Fourth Industrial Revolution and cyber-physical systems, digital images – of machines or processes, for example – are becoming increasingly important. We also research artificial intelligence methods, with which simulations can be calibrated from the data obtained, the condition of machines analyzed, or errors in the production process detected and corrected. Here, too, modeling or simulations are used to increase quality, efficiency and robustness.

In addition to individual consulting, the range of services we offer includes the development of application-specific, digital solutions and their integration into a production environment. 

Stress distribution during Laser Material Deposition.
© Fraunhofer ILT, Aachen, Germany.
Stress distribution during Laser Material Deposition.
Fine cutting - experiment and simulation.
© Fraunhofer ILT, Aachen, Germany.
Fine cutting - experiment and simulation.
Von Mises’ yield criterion for an SLM component.
© Fraunhofer ILT, Aachen, Germany.
Von Mises’ yield criterion for an SLM component.

Applications

  • Concepts for guiding laser manufacturing processes
  • Design of high power laser systems

Process and Component Development

  • Optics, beam guidance and beam shaping
  • Heat conduction and thermomechanics
  • Phase transitions such as melting, solidification, evaporation
  • Fluid dynamics of the melt
  • Simulation of gas flows and nozzle design

Analysis

  • Beam diagnostics, process monitoring and diagnostics
  • Image processing and analysis of experimental data

Process Quality

  • Process window and process limits
  • Process stability
  • Quality from melt
    • Scoring, roughness and dross during cutting
    • Low distortion welding with defined welding depth
    • Low-distortion additive manufacturing
    • Delamination and cracking
  • Damage mechanisms - electronic, thermal, mechanical

Simulation

  • Dynamic process simulation
  • Efficient numerical methods - from laser spot to component
  • Process optimization
    • Solving inverse tasks with neural networks
    • Combination of machine learning (ML) with simulation
    • Metamodeling – process maps
  • Digital hybrid connection – non-metal with metal
  • Ultra-short pulse structuring and separating – first time right – scan strategy
    • Metal
    • Glass and low-Ƙ materials 
    • Semiconducting surface layers
  • In-house high-performance computer cluster
    Computational steering

Markets

Laser technology can solve demanding tasks in many different industries. Whether as a tool in automotive production, as measuring equipment in the environmental sector, as a diagnostic or therapeutic instrument in medical technology or as a communication medium in space technology, the laser provides multiple uses with high productivity and high efficiency.

Read up about the innovations of the Fraunhofer ILT in a few selected industries and convince yourself!

 

Research with us!

Please do not hesitate to contact us if you have any questions about general topics! Our contact persons are happy to get in touch with you.