Electron optical analysis

A further central research focus of the group is the physically grounded beam characterization and the subsequent numerical evaluation of ELO process data (Electron Optical data) for precise analysis and prediction of energy input, surface reconstruction, and component quality in powder bed additive manufacturing processes. Accurate knowledge of the beam profile, power density distribution, and focus position forms the basis for reliable process simulations and reproducible manufacturing strategies.

Building on this beam characterization, numerical models, particularly ray-tracing approaches, are employed. They enable the interpretative evaluation of ELO data obtained during the process and provide predictions of process defects, component accuracy, surface quality, porosity, and process stability. By combining exact beam profiles with simulation-based analysis, the data obtained in situ can be physically interpreted and used to optimize the manufacturing process.

• Markl M., Azadi Tinat MR., Berger T., Renner J., Körner C.:
  Extracting powder bed features via electron optical images during electron beam powder bed fusion
  In: Additive Manufacturing Letters 10 (2024), Article No.: 100220
  ISSN: 2772-3690
  DOI: 10.1016/j.addlet.2024.100220
• Markl M., Azadi Tinat MR., Berger T., Westrich Y., Renner J., Körner C.:
  In-situ electron beam characterization for electron beam powder bed fusion
  In: Additive Manufacturing 96 (2024), Article No.: 104567
  ISSN: 2214-7810
  DOI: 10.1016/j.addma.2024.104567
• Renner J., Markl M., Körner C.:
  In situ build surface topography determination in electron beam powder bed fusion
  In: Progress in Additive Manufacturing (2024)
  ISSN: 2363-9512
  DOI: 10.1007/s40964-024-00621-0
• Baumgärtner B., Rothfelder R., Greiner S., Breuning C., Renner J., Schmidt M., Drummer D., Körner C., Markl M., Hausotte T.:
  Evaluation of Additively-Manufactured Internal Geometrical Features Using X-ray-Computed Tomography
  In: Journal of Manufacturing and Materials Processing (2023)
  ISSN: 2504-4494
  DOI: 10.3390/jmmp7030095
• Renner J., Grund J., Markl M., Körner C.:
  A Ray Tracing Model for Electron Optical Imaging in Electron Beam Powder Bed Fusion
  In: Journal of Manufacturing and Materials Processing 7 (2023), Article No.: 87
  ISSN: 2504-4494
  DOI: 10.3390/jmmp7030087
• Renner J., Breuning C., Markl M., Körner C.:
  Surface topographies from electron optical images in electron beam powder bed fusion for process monitoring and control
  In: Additive Manufacturing 60 (2022), Article No.: 103172
  ISSN: 2214-7810
  DOI: 10.1016/j.addma.2022.103172