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Laser powder bed fusion (LPBF) is an additive manufacturing technique that has gained popularity thanks to its ability to produce geometrically complex, fully dense metal parts. However, these parts are prone to internal defects and…
Additive manufacturing processes are flexible and efficient technologies for producing complex geometries. However, ensuring reliability and repeatability is challenging due to the complex physics and various sources of uncertainty in the…
With a growing demand for high-quality fabrication, the interest in real-time process and defect monitoring of laser powder bed fusion (LPBF) has increased, leading manufacturers to incorporate a variety of online sensing methods including…
Powder-based additive manufacturing techniques provide tools to construct intricate structures that are difficult to manufacture using conventional methods. In Laser Powder Bed Fusion, components are built by selectively melting specific…
Powder Bed Fusion (PBF) is an important Additive Manufacturing (AM) process that is seeing widespread utilization. However, due to inherent process variability, it is still very costly and time consuming to certify the process and the part.…
Metal Laser Powder Bed Fusion (PBF-LB/M) is a leading additive manufacturing technique in which part quality and grain morphology are highly dependent on process parameters. Numerous studies of process variations, such as laser power, scan…
While multiple sensors are used for real-time monitoring in additive manufacturing, not all provide practical or reliable process insights. For example, high-speed X-ray imaging offers valuable spatial information about subsurface melt pool…
We present a data-driven, differentiable neural network model designed to learn the temperature field, its gradient, and the cooling rate, while implicitly representing the melt pool boundary as a level set in laser powder bed fusion. The…
Open-loop control of laser powder bed fusion (LPBF) additive manufacturing (AM) has enabled the production of complex, high-criticality parts for various industries. This method relies on static parameter sets from extensive experimentation…
Laser powder bed fusion (LPBF) process can incur defects due to melt pool instabilities, spattering, temperature increase, and powder spread anomalies. Identifying defects through in-situ monitoring typically requires collecting, storing,…
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…
Additive manufacturing by laser powder bed fusion (LPBF) offers material versatility, capability for complex geometries, and control of mechanical properties and microstructure. However, achieving high-quality output requires process…
An increasing number of laser powder bed fusion machines use off-axis infrared cameras to improve online monitoring and data-driven control capabilities. However, there is still a severe lack of algorithmic solutions to properly process the…
Metal additive manufacturing (AM) by laser powder bed fusion (L-PBF) builds upon fundamentals established in the field of laser welding which include the influence of gas and plume dynamics on weld depth and quality. L-PBF demands a…
Laser powder bed fusion (LPBF) has shown promise for wide range of applications due to its ability to fabricate freeform geometries and generate a controlled microstructure. However, components generated by LPBF still possess sub-optimal…
Development and qualification of process parameters in laser powder bed fusion (LPBF) commonly involves many variables. At the outset of development, whether transferring known parameters to a new machine, or exploring a new material,…
Laser Powder Bed Fusion (L-PBF) is a widely adopted additive manufacturing process for fabricating complex metallic parts layer by layer. Effective thermal management is essential to ensure part quality and structural integrity, as thermal…
Defects in laser powder bed fusion (L-PBF) parts often result from the meso-scale dynamics of the molten alloy near the laser, known as the melt pool. For instance, the melt pool can directly contribute to the formation of undesirable…
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…
This study demonstrates the significant effect of the recoil pressure and Marangoni convection in laser powder bed fusion (L-PBF) of 316L stainless steel. A three-dimensional high fidelity powder-scale model reveals how the strong dynamical…