Physics-Based Multivariable Modeling and Feedback Linearization Control of Melt-Pool Geometry and Temperature in Directed Energy Deposition

Qian Wang, Jianyi Li, Michael Gouge, Abdalla Ramadan Nassar, Panagiotis Michaleris, Edward William Reutzel

Research output: Contribution to journalArticle

12 Citations (Scopus)

Abstract

There has been continuing effort in developing analytical, numerical, and empirical models of laser-based additive manufacturing (AM) processes in the literature. However, advanced physics-based models that can be directly used for feedback control design, i.e., control-oriented models, are severely lacking. In this paper, we develop a physics-based multivariable model for directed energy deposition. One important difference between our model from the existing work lies in a novel parameterization of the material transfer rate in the deposition as a function of the process operating parameters. Such parameterization allows an improved characterization of the steady-state melt-pool geometry compared to the existing lumped-parameter models. Predictions of melt-pool geometry and temperature from our model are validated using experimental data obtained from deposition of Ti-6AL-4V and deposition of Inconel® 718 on a laser engineering net shaping (LENS) AM process and finite-element analysis. Then based on this multivariable model, we design a nonlinear multi-input multi-output (MIMO) control, specifically a feedback linearization (FL) control, to track both melt-pool height and temperature reference trajectories using laser power and laser scan speed.

Original languageEnglish (US)
Article number021013
JournalJournal of Manufacturing Science and Engineering, Transactions of the ASME
Volume139
Issue number2
DOIs
StatePublished - Feb 1 2017

Fingerprint

Feedback linearization
Physics
Geometry
3D printers
Temperature
Lasers
Parameterization
Feedback control
Trajectories
Finite element method

All Science Journal Classification (ASJC) codes

  • Control and Systems Engineering
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

Cite this

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title = "Physics-Based Multivariable Modeling and Feedback Linearization Control of Melt-Pool Geometry and Temperature in Directed Energy Deposition",
abstract = "There has been continuing effort in developing analytical, numerical, and empirical models of laser-based additive manufacturing (AM) processes in the literature. However, advanced physics-based models that can be directly used for feedback control design, i.e., control-oriented models, are severely lacking. In this paper, we develop a physics-based multivariable model for directed energy deposition. One important difference between our model from the existing work lies in a novel parameterization of the material transfer rate in the deposition as a function of the process operating parameters. Such parameterization allows an improved characterization of the steady-state melt-pool geometry compared to the existing lumped-parameter models. Predictions of melt-pool geometry and temperature from our model are validated using experimental data obtained from deposition of Ti-6AL-4V and deposition of Inconel{\circledR} 718 on a laser engineering net shaping (LENS) AM process and finite-element analysis. Then based on this multivariable model, we design a nonlinear multi-input multi-output (MIMO) control, specifically a feedback linearization (FL) control, to track both melt-pool height and temperature reference trajectories using laser power and laser scan speed.",
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AU - Michaleris, Panagiotis

AU - Reutzel, Edward William

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