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Development of control systems for laser powder bed fusion

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Abstract

This article aims to highlight the development of an intermittent controller designed to compensate and rectify the lack of fusion (LoF) zones that are induced during the LPBF process. The initial step involved the usage of the self-organizing map (SOM) algorithm to identify the location of LoF defects. Subsequently, the identified defects undergo clustering through the K-means algorithm to form a matrix of cells on the build plate. The center of each cell that encompasses the defective area is then selected as the optimal position for increasing laser power during the subsequence printed layer. To identify the optimum laser power value, various artificial voids, mimicking actual defects, are embedded in the coupons. The capping layer that closes the artificial void is then fabricated with different laser powers to heal the underlying defects. Based on the optimum laser power and defect size, several controlling rules are defined to change the laser power in situ in the targeted cells located within the capping layer of defects. The change in laser power is transferred as a laser correction file (LCF) to the actuator via the Message Queuing Telemetry Transport (MQTT) broker. Finally, the performance of the controller is evaluated by designing and fabricating two new sets of experiments, including artificial and randomized defects. The results are validated by performing a micro CT scan, in which the density of defects is analyzed on parts produced with and without the controller. The results suggest that the use of the controller increased the density of the sample with randomized defects by up to 1%.

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Funding

The authors received the financial support of the Natural Sciences and Engineering Research Council of Canada (NSERC) Network for Holistic Innovation in Additive Manufacturing (HI-AM).

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Authors and Affiliations

  1. Multi-Scale Additive Manufacturing Lab, University of Waterloo, Waterloo, Canada

    Katayoon Taherkhani & Ehsan Toyserkani

  2. Department of Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo, ON, N2L 3G1, Canada

    Katayoon Taherkhani

  3. EOS, Krailling, Germany

    Gerd Cantzler & Christopher Eischer

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Contributions

The authors confirm contribution to the paper as follows:

- Study conception and design: Katayoon Taherkhani, Gerd Cantzler, Christopher Eischer, Ehsan Toyserkani

- Data collection and analysis: Katayoon Taherkhani, Gerd Cantzler

- Interpretation of results: Katayoon Taherkhani, Christopher Eischer, Ehsan Toyserkani

- Draft manuscript preparation: Katayoon Taherkhani, Ehsan Toyserkani

- Revise the manuscript: Katayoon Taherkhani, Gerd Cantzler, Christopher Eischer, Ehsan Toyserkani

- All authors reviewed the results and approved the final version of the manuscript.

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Taherkhani, K., Cantzler, G., Eischer, C. et al. Development of control systems for laser powder bed fusion. Int J Adv Manuf Technol 129, 5493–5514 (2023). https://doi.org/10.1007/s00170-023-12663-9

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