Model prediction for deposition height during a direct metal deposition process

Jianyi Li, Qian Wang, Panagiotis Michaleris, Edward William Reutzel

Research output: Chapter in Book/Report/Conference proceedingConference contribution

1 Citation (Scopus)

Abstract

There has been increasing demand for the development of lumped-parameter models that can be used for real-time control design and optimization for laser-based additive manufacturing (AM) processes. Our prior work developed a physics-based multivariable model of melt-pool geometry and temperature dynamics for a single-bead deposition in a directed energy deposition process and validated the model using experimental data on deposition of single-bead Ti-6AL-4V (or Inconel®718) tracks on an Optomec® laser engineering net shaping (LENS) system. In this paper, we extend such model for melt-pool geometry on a single-bead single-layer deposition to a multi-bead multi-layer deposition and use the developed model on melt-pool height dynamics to predict part height of three-dimensional builds. Specifically, the extended model incorporates temperature history during the built process, which is computed using temperature field generated from super-positioning of Rosenthal's solution of point heat sources, with one heat source corresponding to one bead built before. The proposed model for part height prediction is then validated using a single-bead thin wall structure built with Ti-6AL-4V using an Optomec® LENS MR-7 system. The model prediction shows good agreement with measurement of part height with less than 10% error rate.

Original languageEnglish (US)
Title of host publication2017 American Control Conference, ACC 2017
PublisherInstitute of Electrical and Electronics Engineers Inc.
Pages2188-2194
Number of pages7
ISBN (Electronic)9781509059928
DOIs
StatePublished - Jun 29 2017
Event2017 American Control Conference, ACC 2017 - Seattle, United States
Duration: May 24 2017May 26 2017

Other

Other2017 American Control Conference, ACC 2017
CountryUnited States
CitySeattle
Period5/24/175/26/17

Fingerprint

Metals
Lasers
3D printers
Geometry
Real time control
Temperature distribution
Physics
Temperature
Hot Temperature

All Science Journal Classification (ASJC) codes

  • Electrical and Electronic Engineering

Cite this

Li, J., Wang, Q., Michaleris, P., & Reutzel, E. W. (2017). Model prediction for deposition height during a direct metal deposition process. In 2017 American Control Conference, ACC 2017 (pp. 2188-2194). [7963277] Institute of Electrical and Electronics Engineers Inc.. https://doi.org/10.23919/ACC.2017.7963277
Li, Jianyi ; Wang, Qian ; Michaleris, Panagiotis ; Reutzel, Edward William. / Model prediction for deposition height during a direct metal deposition process. 2017 American Control Conference, ACC 2017. Institute of Electrical and Electronics Engineers Inc., 2017. pp. 2188-2194
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Li, J, Wang, Q, Michaleris, P & Reutzel, EW 2017, Model prediction for deposition height during a direct metal deposition process. in 2017 American Control Conference, ACC 2017., 7963277, Institute of Electrical and Electronics Engineers Inc., pp. 2188-2194, 2017 American Control Conference, ACC 2017, Seattle, United States, 5/24/17. https://doi.org/10.23919/ACC.2017.7963277

Model prediction for deposition height during a direct metal deposition process. / Li, Jianyi; Wang, Qian; Michaleris, Panagiotis; Reutzel, Edward William.

2017 American Control Conference, ACC 2017. Institute of Electrical and Electronics Engineers Inc., 2017. p. 2188-2194 7963277.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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AB - There has been increasing demand for the development of lumped-parameter models that can be used for real-time control design and optimization for laser-based additive manufacturing (AM) processes. Our prior work developed a physics-based multivariable model of melt-pool geometry and temperature dynamics for a single-bead deposition in a directed energy deposition process and validated the model using experimental data on deposition of single-bead Ti-6AL-4V (or Inconel®718) tracks on an Optomec® laser engineering net shaping (LENS) system. In this paper, we extend such model for melt-pool geometry on a single-bead single-layer deposition to a multi-bead multi-layer deposition and use the developed model on melt-pool height dynamics to predict part height of three-dimensional builds. Specifically, the extended model incorporates temperature history during the built process, which is computed using temperature field generated from super-positioning of Rosenthal's solution of point heat sources, with one heat source corresponding to one bead built before. The proposed model for part height prediction is then validated using a single-bead thin wall structure built with Ti-6AL-4V using an Optomec® LENS MR-7 system. The model prediction shows good agreement with measurement of part height with less than 10% error rate.

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Li J, Wang Q, Michaleris P, Reutzel EW. Model prediction for deposition height during a direct metal deposition process. In 2017 American Control Conference, ACC 2017. Institute of Electrical and Electronics Engineers Inc. 2017. p. 2188-2194. 7963277 https://doi.org/10.23919/ACC.2017.7963277