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Title: 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:
 [1];  [1];  [1];  [2];  [3];  [4];  [5];  [1];  [1]
+ Show Author Affiliations
  1. University of Nebraska, Lincoln, NE (United States)
  2. Stratonics, Inc., Lake Forest, CA (United States)
  3. ARA Engineering, Sedona, AZ (United States)
  4. R3 Digital Sciences, Blacksburg, VA (United States)
  5. 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.
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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
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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.
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@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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https://doi.org/10.1016/j.matdes.2022.110508
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