About this Abstract |
Meeting |
2024 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2024)
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Symposium
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2024 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2024)
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Presentation Title |
Vector-Level Feedforward Control of LPBF Melt Pool Area Using a Physics-based Thermal Model |
Author(s) |
Nathaniel Wood, Nicholas Kirschbaum, Chang-Eun Kim, Thejaswi Tumkur, Chinedum Okwudire |
On-Site Speaker (Planned) |
Nicholas Kirschbaum |
Abstract Scope |
Effective, in-situ process control is a longstanding goal of Laser Powder Bed Fusion (LPBF), and there exists a wealth of research on modulating the laser power in response to measured process signatures like the melt pool area. Ongoing challenges in these efforts include difficulty in making the underlying models flexible, difficulty in preemptively responding to sudden changes in the processing environment, and difficulty accommodating process inputs besides the power. This work presents a novel power-to-meltpool-area controller that addresses these challenges in turn by: (1) Basing it on an accurate and lightweight conduction-based thermal model, which is calibrated irrespective of part geometry by leveraging how it computes the area from the underlying substrate temperature, (2) letting modeled area forecasts preemptively modulate the power instead of merely reacting to existing disturbances, and (3) assigning a uniform signal for each scan vector, which will accommodate inputs like the speed which aren’t continuously-variable. |
Proceedings Inclusion? |
Definite: Post-meeting proceedings |