In-source dynamic beam shaping of Al alloys processed via LPBF: Effect of novel beam profiles on surface roughness and microstructure

Next-generation fiber laser sources can dynamically combine Gaussian beams with ring distributions within the source. The irradiance manipulation may add flexibility to the Laser Powder Bed Fusion process, for instance to control microstructure or surface roughness. However, their use is limited by a lack of studies revealing how beam shaping can be exploited in a reproducible manner. Accordingly, this work shows the use of novel beam profiles provided by a multi-core fiber laser source in the LPBF of AlSi7Mg0.6. Irradiance profiles were characterized, then large experiments were conducted to investigate their effect on surface roughness and microstructure of produced parts.