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Modeling and Control of Layer Height in Laser Wire Additive Manufacturing
Natago Guilé Mbodj1, Mohammad Abuabiah1,2, Peter Plapper1
1Department of Engineering, University of Luxembourg, 6, Rue -Kalergi, L-1359 Luxembourg, Luxembourg.
Materials (Basel, Switzerland)
|July 9, 2022
Summary
A physics-based model for Laser Wire Additive Manufacturing (LWAM) accurately predicts bead geometry. A Model Predictive Controller (MPC) was developed to maintain consistent layer height during large-scale production.
Area of Science:
- Manufacturing Engineering
- Materials Science
- Control Systems
Background:
- Laser Wire Additive Manufacturing (LWAM) offers flexibility and speed for complex metal parts.
- Controlling bead geometry is crucial for the quality of large-scale LWAM products.
- Existing models often lack comprehensive integration of process parameters and thermal history.
Purpose of the Study:
- To develop a physics-based model for LWAM bead geometry.
- To incorporate critical process parameters, material properties, and thermal history.
- To design a Model Predictive Controller (MPC) for stable layer height control.
Main Methods:
- Developed a physics-based model linking process inputs (power, standoff distance, temperature, wire-feed rate, travel speed) to layer height.
- Integrated material properties and thermal history into the model.
- Designed and implemented an MPC to regulate layer height within LWAM constraints.
Main Results:
- The developed physics-based model accurately represents LWAM bead geometry, validated against experimental data.
- The MPC effectively maintained a constant layer height trajectory.
- Controller performance was demonstrated by tracking a predefined layer height reference signal via temperature control.
Conclusions:
- The physics-based model provides a reliable tool for understanding and predicting LWAM bead geometry.
- The MPC successfully addresses layer height variability in large-scale LWAM.
- This integrated modeling and control approach enhances the precision of LWAM processes.
