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Part geometry and conduction-based laser power control for powder bed fusion additive manufacturing
Ho Yeung1, Brandon Lane1, Jason Fox1
1National Institute of Standards and Technology, Gaithersburg, MD, 20899, USA.
Additive Manufacturing
|June 18, 2021
Summary
A new laser power control algorithm for laser powder bed fusion (LPBF) adjusts power based on material proximity, reducing melt pool variations and improving part quality. This method enhances additive manufacturing by optimizing laser energy distribution for better surface finish and reduced distortion.
Area of Science:
- Materials Science
- Mechanical Engineering
- Additive Manufacturing
Background:
- Laser powder bed fusion (LPBF) is an additive manufacturing technique that builds 3D parts layer by layer using a high-power laser.
- Current LPBF processes often result in surface finish defects, part distortion, and residual stress due to simple laser scan strategies and constant power.
- Local variations in melt pool size, shape, and temperature occur, especially near geometric complexities, impacting part integrity.
Purpose of the Study:
- To introduce a novel laser power control algorithm for LPBF that dynamically adjusts laser power.
- To investigate the impact of this algorithm on melt pool stability and part quality.
- To demonstrate the effectiveness of tailored laser power in mitigating common LPBF deficiencies.
Main Methods:
- Development of a geometric conductance factor (GCF) algorithm that calculates laser power based on local solid vs. powder material distribution.
- Implementation of the GCF algorithm on the National Institute of Standards and Technology (NIST) additive manufacturing metrology testbed (AMMT).
- Fabrication of nickel superalloy 625 (IN625) parts using the GCF algorithm with varying parameters and co-axial melt pool monitoring.
Main Results:
- Tailored laser power, controlled by the GCF algorithm, significantly reduced melt pool intensity variability during the 3D build.
- Parts fabricated with the optimized GCF parameters exhibited reduced deflection near overhangs and improved surface finish on down-facing surfaces compared to standard builds.
- In-situ process monitoring confirmed the effectiveness of the algorithm in stabilizing the melt pool.
Conclusions:
- The proposed GCF laser power control algorithm offers a promising approach to enhance LPBF process stability and part quality.
- Dynamic adjustment of laser power based on geometric factors is crucial for overcoming limitations in additive manufacturing.
- This work highlights the potential for optimizing complex laser scan strategies and improving in-situ monitoring for advanced additive manufacturing applications.
