Closed-loop control of meltpool temperature in directed energy deposition

Smoqi, Ziyad; Bevans, Benjamin D.; Gaikwad, Aniruddha; Craig, James; Abul-Haj, Alan; Roeder, Brent; Macy, Bill; Shield, Jeffrey E.; Rao, Prahalada

doi:10.1016/j.matdes.2022.110508

Title: Closed-loop control of meltpool temperature in directed energy deposition

Journal Article · 02 March 2022 · Materials & Design

DOI: https://doi.org/10.1016/j.matdes.2022.110508 · OSTI ID:1977416

Smoqi, Ziyad ^[1]; Bevans, Benjamin D. ^[2]; Gaikwad, Aniruddha ^[2]; Craig, James ^[3]; Abul-Haj, Alan ^[4]; Roeder, Brent ^[5]; Macy, Bill ^[6]; Shield, Jeffrey E. ^[2]; Rao, Prahalada ^[2]

University of Nebraska, Lincoln, NE (United States); Mechanical and Materials Engineering, University of Nebraska-Lincoln, Lincoln, NE, United States
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)

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

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Research Organization:: University of Nebraska, Lincoln, NE (United States)

Sponsoring Organization:: National Science Foundation (NSF); USDOE Office of Science (SC)

Grant/Contract Number:: SC0021136

OSTI ID:: 1977416

Journal Information:: Materials & Design, Journal Name: Materials & Design Journal Issue: C Vol. 215; ISSN 0264-1275

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Title: Closed-loop control of meltpool temperature in directed energy deposition

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