Iterative Process Control for Laser Metal Deposition

该奖项的研究目标是为激光金属沉积（LMD）工艺开发强大的高性能控制算法。 LMD是一类逐层构建金属零件的增材制造工艺，引入了在时间和层域中传播的动态。 传统的控制策略只考虑时域动态特性，而层域动态特性引入了影响过程可靠性和效率的重要部分缺陷。 将在密苏里州ST的LMD机器和Optomec公司的工业LMD机器上创建和验证LMD过程的基于物理的2-D（时域和层域）动态模型。 将开发新的重复过程控制（RPC）算法来控制2-D LMD动态解决鲁棒性和性能问题。 所采用的方法在其他增材和基于层的制造工艺中也可能是有益的。该项目将通过推进LMD过程建模和控制的科学、教育和实践来刺激增材制造的创新，从而可能大幅提高可靠性、效率和生产力。增材制造工艺具有巨大的潜力，可以改变零件的制造方式，从多步手工制造转变为直接从CAD模型进行单步自动化。 特别是LMD工艺是一种至关重要的增材制造工艺，因为它能够以很少的材料浪费生产服务就绪的金属零件，修复高成本零件，并生产功能梯度材料金属零件。 PI将开发一个关于重复过程控制的在线远程课程。研究人员将通过密苏里州ST本科研究项目及其现有的REU增材制造网站直接让本科生参与研究活动。 在OIIS/伊势的共同支持下，PI和研究生将与波兰的研究人员合作，利用专业知识和设施。

The research objective of this award is to develop robust, high-performance control algorithms for Laser Metal Deposition (LMD) processes. LMD is a class of additive manufacturing processes that builds metal parts layer by layer, introducing dynamics that propagate in time and also layer-domains. While conventional control strategies consider only the time-domain dynamics, the layer-domain dynamics introduce significant part defects that affect process reliability and efficiency. Physics-based 2-D (time- and layer-domain) dynamic models of the LMD process will be created and validated on a LMD machine at Missouri S&T and an industrial LMD machine at Optomec, Inc. New Repetitive Process Control (RPC) algorithms will be developed to control the 2-D LMD dynamics addressing issues of robustness and performance. The methodology employed may also be beneficial in other additive and layer-based manufacturing processes. This project will spur innovation in additive manufacturing by advancing the science, education, and practice of LMD process modeling and control, potentially leading to dramatic improvements in reliability, efficiency, and productivity. Additive manufacturing processes hold tremendous potential to transform the way parts are manufactured, away from multi-step hands-on fabrication, to single-step automation directly from CAD models. The LMD process in particular is a critically important additive manufacturing process because it is able to produce service-ready metal parts with little material waste, repair high-cost parts, and produce functional gradient material metal parts. The PI will develop an online distance course on repetitive process control. The investigators will involve undergraduates directly in the research activities through Missouri S&T undergraduate research programs and their existing REU Site in Additive Manufacturing. With the joint support of OIIS/ISE the PI and graduate students will collaborate with researchers in Poland to leverage expertise and facilities.