Additive manufacturing of metals is becoming increasingly important in various industrial sectors, including aviation and space, the energy sector and the automotive and toolmaking industries. More so than with other manufacturing processes, the quality of AM components is based on an in-depth understanding of the interactions between the AM process, the resulting material and the component properties.

This lecture will highlight the coaxial nozzle design approach for powder and wire AM of high-grade materials, including light metals, nickel and titanium alloys, bronze, hard metals or high-entropy alloys. Based on the material properties and the desired component specifications, customized processing heads for coaxial feeding of the material to the laser beam at the working position are available, compatible with conventional laser systems and hybrid AM machines. Some nozzles have been optimized for the use in extreme conditions or confined spaces, while others are designed for particularly fine structures or for high-grade materials. In a recent concept, wire and powder filler material have been combined in one head, opening new horizons in 2D and 3D DED manufacturing. Exemplary components for the aerospace industry as well as high productive laser cladding applications for the automotive and oil and gas industry will be discussed.

Combined Wire and Powder DED for Combinatorial Materials Development and High Productivity LAM

Aerospike engines are a promising type of rocket engine with the potential to significantly improve the efficiency of rocket propulsion systems. Unlike traditional bell-shaped engines, aerospikes have a cone-shaped external contour that allows for more efficient combustion of the propellant in a variety of environmental conditions. The design of aerospike engines presents a challenging task due to their complex internal and external geometries. However, the recent advancements in additive manufacturing (AM) have made it possible to create these complex shapes with greater accuracy and precision. This contribution addresses the complete process&nbsp;chain of an additively manufactured aerospike&nbsp;breadboard engine using kerosene and hydrogen&nbsp;peroxide as propellants. The aerospike was&nbsp;fabricated by laser powder bed fusion (LPBF) using the&nbsp;nickel-based superalloy INCONEL® 718. In order to&nbsp;qualify the material and process for this application,&nbsp;an extensive material characterization campaign&nbsp;including density and roughness measurements,&nbsp;tensile tests at room temperature, 700 °C and&nbsp;900 °C, was conducted. In addition, various&nbsp;geometric features such as triangles, ellipses and&nbsp;circular shapes were generated to determine the&nbsp;maximum unsupported overhang and geometric&nbsp;accuracy. The results were taken into account in the&nbsp;design maturation of the manifold and the cooling&nbsp;channels of the aerospike breadboard engine. Postprocessing&nbsp;included heat treatment, milling, turning&nbsp;and eroding of interfaces, thermal barrier coating (TBC) of&nbsp;thermally stressed surfaces and laser welding of&nbsp;spike and shroud as well as quality assurance.

Process Qualification, Additive Manufacturing, and Post Processing of a Hydrogen Peroxide / Kerosene Aerospike Breadboard Engine

Fast oscillation of the laser beam is an established and proven method for beam shaping to improve laser material processing in terms of machining quality, process stability, and time. In the first part, an overview will be given for available and already proven oscillation devices as 
well as equipment under development. Solutions for beam oscillations in x and y direction as well as solutions for oscillations of the focal plane along the beam propagation direction (z direction) are introduced. Advantages and disadvantages of the various concepts are considered and 
evaluated. 
In the second part, examples will be provided to demonstrate the profitable use of fast laser beam oscillations for the applications of cutting, welding, hardening, and cladding. Finally, opportunities of 3D beam shaping provided by oscillating the beam focus in three spatial directions 
simultaneously or opportunities utilizing x/y oscillations of the laser focal point like a jigsaw are discussed. Consideration is given to whether beam oscillations have the potential to eliminate the need for ever higher laser powers or different wavelength.

Fast Beam Oscillations Improve Laser Material Processing

Additive manufacturing processes have undergone significant development in regard to process management and reproducibility. Porosity, crack formation and similar defects can be reliably avoided through process control for a multitude of materials. This also applies to wire laser direct energy deposition (wire L-DED), which offers standardized feedstock material and direct controllable flow of mass. However, the process inherent microstructure remains fundamentally unaffected by parameter variations within typical process configurations. This microstructure is characterized by coarse columnar grains with a distinct fiber texture along the build direction. The underlying cause is the presence of a strong directional heat flux from the melt pool through the deposited material to the substrate. Consequently, as-built components demonstrate anisotropic mechanical properties with significantly lower tensile strength in build direction.&nbsp;One possible approach to inducing grain refinement and promoting the formation of an isotropic microstructure is the application of ultrasonic waves to the melt pool during solidification This lecture presents an approach to introducing ultrasonic waves to the wire L-DED process. An ultrasound system was developed, integrated in a laser wire deposition machine and a suitable process window has been established. A disruption of the highly directional solidification, resulting in a randomized texture as well as finer grains, has been confirmed by means of scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD) (dm = 284,5 μm without ultrasound, dm = 130,4 μm with ultrasound).

Grain Size Manipulation by Wire Laser Direct Energy Deposition of 316L with Ultrasonic Assistance

Copper is widely used in high heat flux and electrical applications due to the excellent electrical and thermal conductivity properties. Alloying elements such as chromium or nickel are added to strengthen the material especially for higher temperatures. Cu4Cr2Nb or GRCop-42 is a dispersion strengthened alloy developed by NASA for high temperature applications with high thermal and mechanical loads such as rocket engines. Additive manufacturing enables applications with complex functionalised geometries and is especially promising in the aerospace industry. In this contribution, a parametric study was carried out for GRCop-42 and the AM process laser powder bed fusion using a green laser source for two layer thicknesses of 30 and 60 μm. The density, electrical conductivity, macro hardness, microstructure and static mechanical properties were analysed. Various heat treatments in the temperature range of 400 °C and 1000 °C and time range of 30 min to 4 h were tested to increase electrical conductivity and hardness. For both layer thicknesses, dense parameter sets could be obtained with resulting relative densities above 99.8 %. The hardness and electrical conductivity could be tailored depending on the heat treatment in the range of 103 to 219 HV2 and 24 to 88 % International Annealed Copper standard. The highest ultimate tensile strength obtained was 493 MPa. An annealing temperature of 700 °C for 30 min has shown the best combination of room temperature properties such as electrical conductivity of 83.76 %IACS, UTS of 481 MPa, elongation at break at 24 % and hardness of 125 HV2.

Process Development for Laser Powder Bed Fusion of Grcop-42 Using a 515 NM Laser Source

The accelerated electrification of vehicles boosts the demand for sustainable batteries with enhanced energy density. Lithium metal anodes are expected to be a key component for future generation energy storage such as solid state and Lithium sulfur batteries. Energy consumption needs to be further reduced in cell production and substituting the wet electrode processing will be a major step in this direction. As a consequence, innovations in production technologies are required for the manufacturing of future generation batteries. 
Here, we present new concepts for manufacturing of Lithium metal batteries, including coating, cutting and contacting of Lithium anodes as well as dry film processing of composite cathodes. A unique melt deposition process is applied for achieving few micrometer thin Lithium metal films on current collector foils. Further, a laser-based cutting process enables the flexible shaping of Lithium foils and coatings with high edge quality. For direct contacting of Lithium anodes to tabs a low contact resistance and high mechanical strength is achieved via Laser beam joining. Composite cathodes based on various active materials are being produced via the solvent free process DRYtraec®. All process steps are implemented in a semi-automated cell assembly line at Fraunhofer IWS for manufacturing and evaluating Lithium metal battery cells. Thus, the developed technology concepts are being demonstrated in high energy battery cell prototypes exceeding a specific energy of 400 Wh/kg.

Processing Future Generation of Battery Electrodes with Advanced Laser and Coating Technologies

Additive manufacturing is currently paving its way to industrial applications at high pace. While in medical applications there is already a widespread use of AM for customized solutions, the strongest innovation boost in AM is coming from aviation industry, followed by the energy sector, automotive industry, space and toolmaking industry. 
Relying on a strong academic and industrial background in advanced manufacturing technologies, Europe is a strong player in the development of AM machines, processes, materials and components. Major national and European R&D programs as well as company in-house activities have led to successful implementation of AM for functional parts made from polymers, ceramics and metals. 
The aim of this lecture is to highlight selected European AM research initiatives and their research foci, covering the different classes of materials and a wide range of AM processes. Major emphasis is placed on challenges towards industrial implementation, including quality assurance and process certification, high performance materials and structures, multi-material and multi-functional solutions, testing and characterization as well as standardization actions.


Recent Developments in Additive Manufacturing in Europe

LAM: DED Material 2

technical paper

#### Welcome to the 43rd annual ICALEO!

Attention laser enthusiasts, innovators, and industry leaders! Get ready to immerse yourself in the exciting world of lasers at the 43rd annual ICALEO conference. This year, we gathered in the iconic city of Hollywood, California, for cutting-edge technology, groundbreaking presentations, and unparalleled networking opportunities.
Whether you're a seasoned professional or new to the field of photonics, the 43rd annual ICALEO had something for everyone. 

#### General Chair Welcome Message

It is with immense joy and anticipation that I extend a warm welcome to each and every one of you as the General Chair of this year's ICALEO conference.

This year, we find ourselves in the iconic setting of Hollywood, serving as a fitting backdrop for the extraordinary developments in laser technology and applications unfolding in our community.

Our main sessions cover a diverse range of topics, from the intricacies of micro and nano processing to the transformative power of laser additive manufacturing. We will explore the frontiers of battery technology, delve into the intricate world of artificial intelligence, and witness the seamless integration of lasers into these realms.

For those joining us for the first time, we extend an especially heartfelt welcome. ICALEO is not just a conference; it's a convergence of minds, ideas, and innovations. Beyond the formal sessions, I encourage you to engage in informal exchanges. The spirit of discovery and camaraderie is as much a part of the ICALEO experience as the scheduled sessions.

Thank you for being a part of ICALEO 2024. Whether you are a returning participant or a first-time attendee, your presence adds immeasurable value to our vibrant community. May this conference be, this year again, a catalyst for inspiration, collaboration, and breakthroughs that will resonate in our community and beyond.

Eric Mottay 
Congress General Chair, ICALEO 2024


#### About LIA

The Laser Institute of America (LIA) is the professional society for laser applications and safety. Our mission is to foster lasers, laser applications, and laser safety worldwide. Serving the industrial, medical, research and government communities for over 50 years, LIA offers technical information, training and networking opportunities to laser users
from around the globe.

#### About LIA Conferences

The conferences of the Laser Institute of America are the town square of the laser community. A large and diverse group, laser professionals often find themselves disconnected from each other. LIA conferences, however, bring the university researcher, the business executive and the production floor user together under one roof for a unique and
rewarding networking opportunity.

#### Program Tracks
Below is the list of all tracks that were on ICALEO 2024 Conference.

##### Laser Additive Manufacturing
* The Laser Additive Manufacturing (LAM) track is a forum to explore the latest innovations and research in laser-based additive manufacturing (LAM). The Laser Additive Manufacturing track focuses on diverse topics, including laser-based powder bed fusion (PBF-LB), directed energy deposition (DED), and other emerging techniques revolutionizing modern manufacturing processes. From materials science to process optimization, from design innovation to industrial implementation, this track connects researchers, engineers, and industry leaders to exchange insights and share breakthroughs in laser additive manufacturing.

##### Laser Materials Macroprocessing
* The Macroprocessing track comprises some of the most productive laser processing applications. Although these applications have been broadly adopted, researchers and industry are persistently innovating to provide new techniques and novel technologies to advance macro materials processing. The attendees will share and discuss those exciting achievements of their research with peers in these macroscopic specialized sessions.

##### Laser Materials Microprocessing
* The Microprocessing track will consist of papers and talks featuring a wide spectrum of applications and innovative equipment for materials processing in microscales with a strong focus on processes with Short and Ultrashort Pulsed Lasers. The presentations will introduce the latest and greatest advancements in their respective fields, presented by world-leading companies and research organizations. This year we will have talks around the headlines of “Beam shaping”, “Glass”, “Surface processing” and “Drilling” between other topics.

##### Frontiers in Laser Applications
* The Frontier in Laser Applications (FLA) track explores recent, cutting-edge applications of lasers, highlighting innovation at the transition of research and industry. The track has included presentations from a variety of fields: Novel 3-D Printing, Advanced Manufacturing, Laser Manufactured Devices, and Frontiers in Laser Processing. The sessions under the Frontier in Laser Application track promise to bring diverse and unique perspectives from real-world applications across laser manufacturing.

##### Laser in Battery Manufacturing
* Electrification is crucial to address global environmental challenges. The laser plays a key role in most manufacturing steps in battery production with all possible laser applications from ablation, structuring, welding, cutting, and marking. Further improvements in the batteries’ power densities, fast charging properties, and yield in battery production are related to photonics and, thus, lasers. We will hear and discuss the latest developments in research, development, and industrial applications. Join us for this year’s Battery Track.

##### Artifical Intelligence in Laser Processing
* The track ‘Artificial Intelligence in Laser Processing’ at ICALEO 2024 explores the fusion of AI and laser manufacturing. Discover cutting-edge research on optimizing laser processes and enhancing manufacturing efficiency. Explore AI’s diverse applications in parameter optimization, quality prediction, real-time process monitoring, and control. Join us to unlock the potential of AI-driven solutions revolutionizing laser materials processing, delivering unprecedented precision, productivity, and innovation.

To access the site please register [**here**](https://icaleo.org/attend). 

Are you an LIA Member? Find a special discount code in your LIA account at https://www.lia.org/user to apply to your registration for additional savings!

Please register for the ICALEO 2024 Conference to join the event.

ICALEO 2024

Attention laser enthusiasts, innovators, and industry leaders! Get ready to immerse yourself in the exciting world of lasers at the 43rd annual ICALEO conference. 

LAM Track: PBFAM Process and Materials I

**General Chair Welcome**

![](https://assets.underline.io/markdown_image/1/image/d6e6dddc08bf2371b9136ea9c18dc5ab.png)              

Welcome to ICALEO® 2023!
	
We were excited to host the world’s leading international conference on Lasers and Electro-Optics in Chicago. The Laser has been shown to have the potential to revolutionize solutions for major global challenges like energy usage and supply, global warming, and CO2 footprint. Even the fusion energy breakthrough is based on laser technology. The conference, with peer-reviewed scientific and technical presentations, focused on the newest results in Micro Applications, Macro Applications, Additive Manufacturing, Beam Shaping and Frontiers in Laser Applications. Additionally, the Battery-Manufacturing Track gave an overview of the process combined with the newest advances in laser application results. 

The Business Session brought the business aspect and environment of the laser to the audience and the possibility to discuss with seasoned industry leaders from around the world. 

Whether this is the first time you are hearing about ICALEO or you are a longtime attendee, you will find something of interest, new ideas, and an excellent opportunity to network with other laser specialists worldwide. 

**Klaus Löffler **  
ICALEO General Chair   
Managing Director, Precitec GmbH

**What is ICALEO?**

ICALEO® brings together the brightest minds, seasoned professionals, and pioneering researchers from around the world. With a laser-focused agenda, ICALEO offers an exceptional platform to delve into the cutting-edge advancements, diverse applications, and transformative research that define lasers and electro-optics.

Participants will be immersed in a dynamic environment that fosters collaborative learning, networking, and idea exchange. Through engaging plenary presentations, technical sessions, an industry business panel, and networking events, attendees gain insights into the forefront of laser technology. From industrial applications to medical breakthroughs, additive manufacturing to materials processing, ICALEO covers the entire spectrum of laser-related disciplines. Moreover, the event serves as a launching pad for synergistic partnerships, paving the way for professionals to forge connections that shape the future of our industry.

Join us in Chicago and be part of an unparalleled gathering that challenges the boundaries of possibility within lasers and electro-optics. As we convene to share knowledge, explore innovations, and cultivate collaborations, ICALEO stands as a pivotal force driving the evolution of this transformative technology.

**Who attended?**

ICALEO is tailor-made for professionals, researchers, academics, and enthusiasts who are deeply passionate about the world of lasers and electro-optics. If you're an industry trailblazer, an academic luminary, an aspiring expert, or a postgraduate student looking to dive into the latest developments and trends, this is an event you won't want to miss.

Industrial leaders seeking to stay ahead of the curve in their fields, engineers working on laser applications, and manufacturing experts interested in additive manufacturing and materials processing will find ICALEO to be an invaluable platform. Researchers and scientists exploring the forefront of laser technology, from fundamental principles to groundbreaking applications, will also discover a wealth of knowledge and networking opportunities.

Medical professionals investigating laser-based medical advancements, entrepreneurs seeking to innovate with lasers, educators aiming to stay updated with the latest in laser education, and policy makers shaping the industry's landscape are all essential attendees. Whether you're an established expert or a rising star, the 42nd annual ICALEO promises to offer a diverse ecosystem of expertise, connections, and knowledge sharing that caters to the laser and electro-optics communities.

**Fields Represented:**

* Entrepreneurs and Innovators
* Manufacturing Experts
* Students and Graduates
* Policy Makers and Regulators
* Consultants and Advisors
* Technology Enthusiasts
* Suppliers and Manufacturers
* Startups and Innovators
* Researchers in Laser Education

**[View All Proceedings Here](https://icaleo.conferencespot.org/event-data)**

### **Program Tracks & Chairs**

To access the site please register [**here**](https://icaleo.org/attend). 

Please register for the ICALEO 2023 Conference to join the event.

ICALEO 2023

ICALEO® brings together the brightest minds, seasoned professionals, and pioneering researchers from around the world. With a laser-focused agenda, ICALEO offers an exceptional platform to delve into the cutting-edge advancements, diverse applications, and transformative research that define lasers and electro-optics.

Beam shaping: Improving Laser Beam Welding with Beam Shaping

LAM Track: DEDAM Process and Materials II

**Session Chair: **Hortense Le Ferrand

SYM O - Materials for Additive Manufacturing

**Please view our Welcome to MH21 video.**

<center>
<figure class="video_container">
	 <iframe src="https://screencast-o-matic.com/watch/cr1UYHV1pcz?v=6&ff=1&title=0&controls=1" width=826 height=526 frameborder="0" allowfullscreen="true"> </iframe>
</figure>
	</center>


**Walkthrough Video**

Here is a Walkthrough showing how to navigate the conference and network with others 

<center>
<figure class="video_container">
	 <iframe src="https://screencast-o-matic.com/watch/cr1vnrV1paE?v=6&ff=1&title=0&controls=1" width=826 height=526 frameborder="0" allowfullscreen="true"> </iframe>
</figure>
	</center>




	 Organized by
 
<a href="https://mrs.org.sg/">
<img src="https://assets.underline.io/uploads/markdown_image/1/image/95d5789689d5f900b90e9fe54ea3cf0d.jpg"</a>

 
	
	 In association with
 
<a href="http://www.ntu.edu.sg/">
<img src="https://assets.underline.io/uploads/markdown_image/1/image/334cd171ad2fdee033c635b368e5e160.png"</a>
	<a href="https://www.nus.edu.sg/">
<img src="https://assets.underline.io/uploads/markdown_image/1/image/32e6f82c0440f7bb24c590f9f67821bd.png"</a>
		<a href="https://www.a-star.edu.sg/">
<img src="https://assets.underline.io/uploads/markdown_image/1/image/72557865b589cfa3d2a0243ffce4a270.png"</a>
	
 


	 Supported by
 
		 <a href="https://www.visitsingapore.com/mice/en/about-us/about-secb/">
<img src="https://assets.underline.io/uploads/markdown_image/1/image/6e679842ead62be522ba6a630b82d5c9.png"</a>

To access the MH 21 Conference, [please register](https://mh21.mrs.org.sg/event/da3f9651-429f-4763-81b2-ebd7311b6bc8/websitePage:206f7605-1731-41f9-8421-56d3890f398f)

MATERIALS FOR HUMANITY (MH 21)

MH 21 is arranged around 6 themes that focus attention on pressing needs that should be addressed to enhance the well-being of communities and provide a forum for presenting breakthrough discoveries.

Christoph Leyens

7

5

SHORT BIO

Presentations

Combined Wire and Powder DED for Combinatorial Materials Development and High Productivity LAM

Process Qualification, Additive Manufacturing, and Post Processing of a Hydrogen Peroxide / Kerosene Aerospike Breadboard Engine

Fast Beam Oscillations Improve Laser Material Processing

Grain Size Manipulation by Wire Laser Direct Energy Deposition of 316L with Ultrasonic Assistance

Process Development for Laser Powder Bed Fusion of Grcop-42 Using a 515 NM Laser Source

Processing Future Generation of Battery Electrodes with Advanced Laser and Coating Technologies

Recent Developments in Additive Manufacturing in Europe

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