Iterative simulation-based techniques for control of laser powder bed fusion additive manufacturing
Iterative simulation-based techniques for control of laser powder bed fusion additive manufacturing
复制标题
基于迭代仿真的激光粉末床熔融增材制造控制技术
DOI：
10.1016/j.addma.2021.102078
复制
发表时间：
2021
影响因子：
11
通讯作者：
Stutzman, Christopher B.
中科院分区：
文献类型：
--
作者：
Irwin, Jeff E.;Wang, Qian;Michaleris, Panagiotis;Nassar, Abdalla R.;Ren, Yong;Stutzman, Christopher B.
热控制是激光粉末床熔融增材制造过程控制的难点之一。过低的激光功率可能导致不完全熔化，过高的激光功率可能导致锁孔，增加零件的孔隙率。考虑到我们之前工作的热有限元模型，本文提出并实现了一种基于割线的迭代方法来控制模拟的激光功率以达到恒定的熔池大小。利用EOSINT M280系统设计并构建了Inconel 625的几个实验样品，并对其进行了截面分析，以评估基于迭代仿真的激光功率控制器的有效性。横截面积统计数据是在激光转弯附近收集的，在那里熔池是最动态的。与在所有配置中使用恒定激光功率相比，基于迭代仿真的控制器将熔池尺寸的变化减少了13.4%至48.8%。加上割线法的额外迭代，控制下的模拟时间大约是恒定激光功率下模拟时间的2.3倍。
One of the challenges for process control of laser powder bed fusion additive manufacturing lies in thermal control. Excessively low laser power may lead to incomplete melting, while too high laser power can lead to keyholing, increasing the porosity of parts. Considering a thermal finite-element model from our prior work, a secant-based iterative method is proposed and implemented in this work to control the simulated laser power to attain a constant melt-pool size. Several experimental samples of Inconel 625 are designed and built with the EOSINT M280 system, and cross-sectioned to evaluate the effectiveness of the iterative simulation-based controller of laser power. Cross-sectional area statistics are collected near laser turnarounds, where the melt pool is most dynamic. The iterative simulation-based controller reduces the variation of melt pool size by between 13.4% and 48.8% compared to applying constant laser power for all configurations. With the extra iterations from the secant method, the controlled simulations take roughly 2.3 times longer than the simulations under constant laser power.
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