KTEK0033 Materials Processing Technologies in Digital Manufacturing
University of Turku, Department of Mechanical and Materials Engineering, 2026
📘 Lecture Contributions (UTU)
🔹 Module 1: Laser Cutting & Process Physics
🔥 Cutting Mechanisms: Explores the fundamental physics of sublimation, photochemical ablation, and fusion cutting, linking energy balance to material removal efficiency.
⚙️ Engineering Control: Analyzes the role of laser parameters (power, focus, polarization) and assist-gas dynamics (Oxygen vs. Nitrogen) in governing kerf geometry, dross formation, and the Heat Affected Zone (HAZ).
🔹 Module 2: Laser Powder Bed Fusion (LPBF)
🏗️ Energy Scaling: Evaluates the use of Volumetric Energy Density (VED) versus Normalized Enthalpy to predict part quality and melt pool stability.
🔬 Solidification Dynamics: Details the relationship between thermal gradients (G) and growth velocity (R) in rapid solidification, explaining the formation of unique LPBF microstructures.
🔹 Module 3: Directed Energy Deposition (DED)
⚡ Working Principles: Covers laser-powder interaction, powder catchment efficiency, and the physics of layer-wise deposition in blown-powder and wire-fed systems.
🧪 Metallurgical Quality: Focuses on dilution control, wetting angles, and grain refinement through cooling rate management, linking solidification behavior to Hall-Petch strengthening.
🔹 Module 4: Electron Beam Technology
🌌 Vacuum Physics: Contrasts electron-based collisional heating with laser absorption, focusing on the advantages of vacuum operation for oxidation prevention and plume stability.
🎯 Beam Control: Compares magnetic beam deflection to optical galvo scanning, emphasizing near-surface volumetric heating and high-speed preheating strategies.
🔹 Module 5: Field-Assisted Manufacturing (FALM)
🌀 Process Regulation: Introduces hybrid techniques where external fields act as "regulators" for the melt pool. Topics include using Magnetic Fields (Lorentz force) to stabilize keyholes and Ultrasonic Fields (cavitation) to refine grain structures.
🛠️ Advanced Control: Explores Electric and Thermal field assistance (Joule heating) to reduce flow stress and enhance the processability of difficult-to-machine alloys like Inconel and Titanium.
🔹 Course Integration
These modules provide a comprehensive surface-to-volume understanding of modern manufacturing. By mastering these process–structure–property relationships, students are equipped to justify process selection and optimize operating windows for productivity, quality, and sustainability.