Related papers: Vector-level Feedforward Control of LPBF Melt Pool…
Laser powder bed fusion (LPBF) holds promise to efficiently produce metal parts. However, LPBF incurs stochastic melt pool (MP) spattering, which would roughen workpiece in-process surface, thus weakening inter-layer bonding and causing…
Limited process control can cause metallurgical defect formation and inhomogeneous relative density in laser powder bed fusion manufactured parts. In this study, cylindrical 15-5 PH stainless steel specimens are investigated by computer…
Overheating anomaly detection is essential for the quality and reliability of parts produced by laser powder bed fusion (LPBF) additive manufacturing (AM). In this research, we focus on the detection of overheating anomalies using…
Selective laser melting is a promising additive manufacturing technology enabling the fabrication of highly customizable products. A major challenge in selective laser melting is ensuring the quality of produced parts, which is influenced…
A hybrid (i.e., physics-guided data-driven) feedforward tracking controller is proposed for systems with unmodeled linear or nonlinear dynamics. The controller is based on the filtered basis function (FBF) approach, hence it is called a…
Laser powder bed fusion (L-PBF) of semi-crystalline polymers such as polyamide-12 (PA12) has found increasing use in various industrial applications. However, achieving high dimensional accuracy remains a significant challenge. Despite the…
Selective Laser Melting (SLM) is an additive manufacturing technology that builds three dimensional parts by melting layers of metal powder together with a laser that traces out a desired geometry. SLM is popular in industry, however the…
In context of laser powder bed fusion (L-PBF), it is known that the properties of the final fabricated product highly depend on the temperature distribution and its gradient over the manufacturing plate. In this paper, we propose a novel…
This study investigates the stabilization of interlayer temperature in the laser powder bed fusion process through a novel switched layer-to-layer closed-loop feedback controller. The controller architecture aims to measure the interlayer…
We present a computational framework for the simulations of powder-bed fusion of metallic alloys, which combines: (1) CalPhaD calculations of temperature-dependent alloy properties and phase diagrams, (2) macroscale finite element (FE)…
Powder bed fusion (PBF) is an emerging metal additive manufacturing (AM) technology that enables rapid fabrication of complex geometries. However, defects such as pores and balling may occur and lead to structural unconformities, thus…
Achieving desired mechanical properties in additive manufacturing requires many experiments and a well-defined design framework becomes crucial in reducing trials and conserving resources. Here, we propose a methodology embracing the…
Emission of blackbody emission from the meltpool and surrounding area in laser powder bed fusion (LPBF) makes this process visible to a range of optical monitoring instruments intended for online process and quality control. Yet, these…
The stochastic formation of defects during Laser Powder Bed Fusion (L-PBF) negatively impacts its adoption for high-precision use cases. Optical monitoring techniques can be used to identify defects based on layer-wise imaging, but these…
Part II of the present work concerns modeling and analyzing the experimental data obtained in Part I. A computational fluid dynamics (CFD) model of two-dimensional conductive heat transfer and thermocapillary-driven convection is developed.…
Laser powder bed fusion (LPBF) is an additive manufacturing (AM) technology. To achieve high product quality, the powder is best spread as a uniform, dense layer. The challenge for LPBF manufacturers is to develop a spreading process that…
In this paper we outline the development of a scalable PBF thermal history simulation built on CAPL and based on melt pool physics and dynamics. The new approach inherits linear scalability from CAPL and has three novel ingredients.…
In our study, molecular dynamics (MD) simulations of laser powder bed fusion (LPBF) have been conducted on equimolar FeNiCr medium entropy alloy (MEA) powders. With the development of newer LPBF technologies capable of printing at the…
Thermal multi-phase flow simulations are indispensable to understanding the multi-scale and multi-physics phenomena in metal additive manufacturing (AM) processes, yet accurate and robust predictions remain challenging. This book chapter…
Metal additive manufacturing (AM) processes, such as laser powder bed fusion (L-PBF), can yield high-value parts with unique geometries and features, substantially reducing costs and enhancing performance. However, the material properties…