Power prediction for laser engineered net shaping of Al2O3 ceramic parts

Laser-aided additive manufacturing technique is a competitive method for direct fabrication of ceramic components. However, the optimal processing parameters are difficult to find because defects are easy to generate for ceramic parts. This paper proposes a mathematical model for predicting required laser power in direct fabrication of Al2O3 ceramic parts by laser engineered net shaping (LENS). The laser power model, which is derived based on energy balance of one deposition layer, reveals the relationship between laser power and other process conditions, such as powder flow rate, nozzle travel speed and physical properties of deposited material. The proposed model was then verified through a fabrication experiment of several single-bead wall Al2O3 ceramic parts with different laser power. Experimental results indicate that the laser power predicted by the model is accurate for different processing conditions. This model provides a new yet simple method for predicting required laser power accurately during LENS processes.