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A comparison of selective laser sintering (SLS) and selective laser cladding (SLC) methods is presented. Loose single‐component, Ni‐alloy powder was used in this study. The powder feeding system formed the flow of powder particles directed into the zone of laser spot. The particles were deposited directly onto a substrate or onto the top of a pedestal. The powders were treated with a CW‐ Nd:YAG laser (λ=1.06 μm). The beam was motionless relative to the powder bed. As a result, the samples of sintered or remelted powders were built up as the vertical rods. The geometrical characteristics, structure and mechanical properties of samples were investigated.

The particularities of the selective laser processing of single‐component metal powder layers were investigated, especially the occurrence of the balling‐processes under different processing conditions. During laser processing, sintered, semi‐sintered/semi‐melted or completely melted cakes can be formed. Size and shape of the laser processed parts can change depending on the energy and time parameters of the laser irradiation and on the properties of initial powder layers.

The normal spectral absorptance of a number of metal, ceramic and polymer powders susceptible to be utilised for selective laser sintering (SLS) technique was experimentally determined. The measurements were performed with two laser wavelengths of 1.06μm and 10.6μm obtained by using two lasers – Nd‐YAG and CO₂ respectively. The change in the powder absorptance with time during laser processing was also investigated. The effect of the absorptance characteristics on the sintering process is discussed.

This paper aims to propose methods for on-line monitoring and process quality assurance of Selective Laser Melting (SLM) technology as a competitive advantage to enhance its implementation into modern manufacturing industry.

Monitoring of thermal emission from the laser impact zone was carried out by an originally developed pyrometer and a charge-coupled device (CCD) camera which were integrated with the optical system of the PHENIX PM-100 machine. Experiments are performed with variation of the basic process parameters such as powder layer thickness (0-120 μm), hatch distance (60-1,000 μm) and fabrication strategy (the so-called “one-zone” and “two-zone”).

The pyrometer signal from the laser impact zone and the 2D temperature mapping from HAZ are rather sensible to variation of high-temperature phenomena during powder consolidation imposed by variation of the operational parameters.

Pyrometer measurements are in arbitrary units. This limitation is due to the difficulty to integrate diagnostic tools into the optical system of a commercial SLM machine.

Enhancement of SLM process stability and efficiency through comprehensive optical diagnostics and on-line control.

High-temperature phenomena in SLM were monitored coaxially with the laser beam for variation of several operational parameters.