Physics-based Control-oriented Multiscale Modeling of Laser Powder Bed Fusion Additive Manufacturing

基于物理的控制导向的激光粉末床熔融增材制造多尺度建模

• 批准号: 2015930
• 负责人: Qian Wang
• 金额: $ 54.68万
• 依托单位: Pennsylvania State Univ University Park
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2020
• 资助国家: 美国
• 起止时间: 2020-09-01 至 2024-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2015930&HistoricalAwards=false
• 关键词: Physics; based; Control; oriented; Multiscale

Laser powder bed fusion additive manufacturing processes are one important category of additive manufacturing processes for metal parts. They are used for the production of high-value components with complex geometries across the medical, aerospace, and automotive industries. This award will support fundamental research that contributes to new models of the laser powder bed fusion additive manufacturing process, which can be used to improve the real-time control of the processes on commercial systems. Outcomes of this project will improve part quality and process consistence, reduce part rejections and material waste, and thus have the potential to increase economic competitiveness of the manufacturing industry of the United States. This award will support the integration of education and research, and outreach activities to help bridge the gap between academic research and industrial end uses of additive manufacturing processes, and to train the next generation of workforce for innovations in the manufacturing industry. The main contribution of this project lies in the novel first-principle, control-oriented multiscale model for the laser powder bed fusion additive manufacturing processes, from the fine scale to the layer scale and then to the part scale. This multiscale model is able to capture the essential physics of the laser powder bed fusion additive manufacturing processes, but with a significantly reduced computation complexity compared to finite element models. More importantly, it enables the derivation of an analytical expression of feed-forward or feedback controller of laser power to regulate the melt-pool geometry and thus to improve the build quality. In addition to developing the multiscale model, the research team will also perform experimental validation of the modeling effort and demonstration of the control implementation on a commercial laser powder bed fusion additive manufacturing system.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

激光粉末床熔融增材制造工艺是金属零件增材制造工艺的一个重要类别。它们用于生产医疗、航空航天和汽车行业中具有复杂几何形状的高价值部件。该奖项将支持有助于激光粉末床熔融增材制造工艺新模型的基础研究，该工艺可用于改善商业系统上工艺的实时控制。该项目的成果将提高零件质量和工艺一致性，减少零件报废和材料浪费，从而有可能提高美国制造业的经济竞争力。该奖项将支持教育和研究的整合，以及推广活动，以帮助弥合学术研究和增材制造工艺的工业最终用途之间的差距，并为制造业的创新培养下一代劳动力。该项目的主要贡献在于为激光粉末床熔融增材制造过程建立了新颖的第一原理、面向控制的多尺度模型，从精细尺度到层尺度，再到零件尺度。这种多尺度模型能够捕获激光粉末床熔融增材制造过程的基本物理特性，但与有限元模型相比，计算复杂性显著降低。更重要的是，它能够推导出一个解析表达式的前馈或反馈控制器的激光功率调节熔池的几何形状，从而提高构建质量。除了开发多尺度模型外，研究团队还将对建模工作进行实验验证，并在商业激光粉末床聚变增材制造系统上演示控制实施。该奖项反映了NSF的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

项目成果

A finite difference method for fast prediction and control of part-scale temperature evolution in laser powder bed fusion

• DOI: 10.1016/j.jmapro.2023.03.020
• 发表时间: 2023-05
• 期刊: Journal of Manufacturing Processes
• 影响因子: 6.2
• 作者: Yong Ren;Qianqian Wang

Iterative simulation-based techniques for control of laser powder bed fusion additive manufacturing

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
• 发表时间: 2021
• 期刊: Additive Manufacturing
• 影响因子: 11
• 作者: Irwin, Jeff E.;Wang, Qian;Michaleris, Panagiotis;Nassar, Abdalla R.;Ren, Yong;Stutzman, Christopher B.
• 通讯作者: Stutzman, Christopher B.

Part-scale thermal evolution and post-process distortion of Inconel-718 builds fabricated by laser powder bed fusion

通过激光粉末床熔融制造的 Inconel-718 结构的部分尺寸热演化和后处理变形

• DOI: 10.1016/j.jmapro.2022.07.026
• 发表时间: 2022
• 期刊: Journal of manufacturing processes
• 影响因子: 6.2
• 作者: Wang, Q.;Michaleris, P.;Pantano, M.;Li, C.;Ren, Y.;Nassar, A. R.
• 通讯作者: Nassar, A. R.

Gaussian-process based modeling and optimal control of melt-pool geometry in laser powder bed fusion

激光粉末床熔合中熔池几何形状的基于高斯过程的建模和优化控制

• DOI: 10.1007/s10845-021-01781-4
• 发表时间: 2021
• 期刊: Journal of Intelligent Manufacturing
• 影响因子: 8.3
• 作者: Ren, Yong;Wang, Qian
• 通讯作者: Wang, Qian