Closed-loop control of meltpool temperature in directed energy deposition
Abstract
The objective of this work is to mitigate flaw formation in powder and laser-based directed energy deposition (DED) additive manufacturing process through close-loop control of the meltpool temperature. In this work, the meltpool temperature was controlled by modulating the laser power based on feedback signals from a coaxial two-wavelength imaging pyrometer. The utility of closed-loop control in DED is demonstrated in the context of practically inspired trapezoid-shaped stainlesssteel parts (SS 316L). We demonstrate that parts built under closed-loop control have reduced variation in porosity and uniform microstructure compared to parts built under open-loop conditions. For example, post-process characterization showed that closed-loop processed parts had a volume percent porosity ranging from 0.036% to 0.043%. In comparison, open-loop processed parts had a larger variation in volume percent porosity ranging from 0.032% to 0.068%. Further, parts built with closed-loop processing depicted consistent dendritic microstructure. By contrast, parts built with open-loop processing showed microstructure heterogeneity with the presence of both dendritic and planar grains, which in turn translated to large variation in microhardness
- Authors:
-
- University of Nebraska, Lincoln, NE (United States)
- Stratonics, Inc., Lake Forest, CA (United States)
- ARA Engineering, Sedona, AZ (United States)
- R3 Digital Sciences, Blacksburg, VA (United States)
- Macy Consulting, St. Louis, MO (United States)
- Publication Date:
- Research Org.:
- Univ. of Nebraska, Lincoln, NE (United States)
- Sponsoring Org.:
- USDOE Office of Science (SC); National Science Foundation (NSF)
- OSTI Identifier:
- 1977416
- Grant/Contract Number:
- SC0021136; OIA-1929172; CMMI-1719388; CMMI-1920245; CMMI-1739696; ECCS-2020246; PFI-TT 2044710; CMMI-1752069; ECCS: 2025298
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Materials & Design
- Additional Journal Information:
- Journal Volume: 215; Journal Issue: C; Journal ID: ISSN 0264-1275
- Publisher:
- Elsevier
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; directed energy deposition; closed-loop control; meltpool temperature; dual-wavelength pyrometer; microstructure; porosity
Citation Formats
Smoqi, Ziyad, Bevans, Benjamin D., Gaikwad, Aniruddha, Craig, James, Abul-Haj, Alan, Roeder, Brent, Macy, Bill, Shield, Jeffrey E., and Rao, Prahalada. Closed-loop control of meltpool temperature in directed energy deposition. United States: N. p., 2022.
Web. doi:10.1016/j.matdes.2022.110508.
Smoqi, Ziyad, Bevans, Benjamin D., Gaikwad, Aniruddha, Craig, James, Abul-Haj, Alan, Roeder, Brent, Macy, Bill, Shield, Jeffrey E., & Rao, Prahalada. Closed-loop control of meltpool temperature in directed energy deposition. United States. https://doi.org/10.1016/j.matdes.2022.110508
Smoqi, Ziyad, Bevans, Benjamin D., Gaikwad, Aniruddha, Craig, James, Abul-Haj, Alan, Roeder, Brent, Macy, Bill, Shield, Jeffrey E., and Rao, Prahalada. Wed .
"Closed-loop control of meltpool temperature in directed energy deposition". United States. https://doi.org/10.1016/j.matdes.2022.110508. https://www.osti.gov/servlets/purl/1977416.
@article{osti_1977416,
title = {Closed-loop control of meltpool temperature in directed energy deposition},
author = {Smoqi, Ziyad and Bevans, Benjamin D. and Gaikwad, Aniruddha and Craig, James and Abul-Haj, Alan and Roeder, Brent and Macy, Bill and Shield, Jeffrey E. and Rao, Prahalada},
abstractNote = {The objective of this work is to mitigate flaw formation in powder and laser-based directed energy deposition (DED) additive manufacturing process through close-loop control of the meltpool temperature. In this work, the meltpool temperature was controlled by modulating the laser power based on feedback signals from a coaxial two-wavelength imaging pyrometer. The utility of closed-loop control in DED is demonstrated in the context of practically inspired trapezoid-shaped stainlesssteel parts (SS 316L). We demonstrate that parts built under closed-loop control have reduced variation in porosity and uniform microstructure compared to parts built under open-loop conditions. For example, post-process characterization showed that closed-loop processed parts had a volume percent porosity ranging from 0.036% to 0.043%. In comparison, open-loop processed parts had a larger variation in volume percent porosity ranging from 0.032% to 0.068%. Further, parts built with closed-loop processing depicted consistent dendritic microstructure. By contrast, parts built with open-loop processing showed microstructure heterogeneity with the presence of both dendritic and planar grains, which in turn translated to large variation in microhardness},
doi = {10.1016/j.matdes.2022.110508},
journal = {Materials & Design},
number = C,
volume = 215,
place = {United States},
year = {Wed Mar 02 00:00:00 EST 2022},
month = {Wed Mar 02 00:00:00 EST 2022}
}
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