Process control and further improvements for the blown powder process

The Blown Powder Process is a new way of laser assisted Rapid Tooling. Material properties of the produced models or tools are mostly determined by the properties of the base metal powder, while process parameters show almost no influence.The process behaviour can be improved by adequate process control. With a temperature control a constant melt pool temperature could be achieved. Different types of distance control systems were implemented and compared. An image process system was easily installed and operated while a distance measuring system based on the optical back scattered radiation provided higher precision.Finally, optimum powder catchment rate and surface quality were achieved by improving the powder nozzle system, based on FV-analysis.The Blown Powder Process is a new way of laser assisted Rapid Tooling. Material properties of the produced models or tools are mostly determined by the properties of the base metal powder, while process parameters show almost no influence.The process behaviour can be improved by adequate process control. With a temperature control a constant melt pool temperature could be achieved. Different types of distance control systems were implemented and compared. An image process system was easily installed and operated while a distance measuring system based on the optical back scattered radiation provided higher precision.Finally, optimum powder catchment rate and surface quality were achieved by improving the powder nozzle system, based on FV-analysis.