Intra-layer closed-loop control of build plan during directed energy additive manufacturing of Ti-6Al-4V

Research output: Contribution to journalArticle

30 Citations (Scopus)

Abstract

The location, timing, and arrangement of depositions paths used to build an additively manufactured component - collectively called the build plan - are known to impact local thermal history, microstructure, thermal distortion, and mechanical properties. In this work, a novel system architecture for intra-layer, closed-loop control of the build plan is introduced and demonstrated for directed-energy deposition of Ti-6Al-4V. The control strategy altered the build plan in real time to ensure that the temperature around the start point of each hatch, prior to deposition, was below a threshold temperature of 415. °C. Potential hatches with an initial temperature above this threshold were temporarily skipped. Compared with open-loop processing, closed-loop control resulted in vertical alignment of columnar prior-β grains, more uniform α-lath widths, and more-uniform microhardness values within the deposited component.

Original languageEnglish (US)
Pages (from-to)39-52
Number of pages14
JournalAdditive Manufacturing
Volume6
DOIs
StatePublished - Apr 1 2015

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3D printers
Hatches
Microhardness
Temperature
Mechanical properties
Microstructure
Processing
Hot Temperature

All Science Journal Classification (ASJC) codes

  • Biomedical Engineering
  • Materials Science(all)
  • Engineering (miscellaneous)
  • Industrial and Manufacturing Engineering

Cite this

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abstract = "The location, timing, and arrangement of depositions paths used to build an additively manufactured component - collectively called the build plan - are known to impact local thermal history, microstructure, thermal distortion, and mechanical properties. In this work, a novel system architecture for intra-layer, closed-loop control of the build plan is introduced and demonstrated for directed-energy deposition of Ti-6Al-4V. The control strategy altered the build plan in real time to ensure that the temperature around the start point of each hatch, prior to deposition, was below a threshold temperature of 415. °C. Potential hatches with an initial temperature above this threshold were temporarily skipped. Compared with open-loop processing, closed-loop control resulted in vertical alignment of columnar prior-β grains, more uniform α-lath widths, and more-uniform microhardness values within the deposited component.",
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AU - Nassar, Abdalla Ramadan

AU - Keist, Jayme Scot

AU - Reutzel, Edward William

AU - Spurgeon, Todd J.

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