Layer-to-layer closed-loop feedback control application for inter-layer temperature stabilization in laser powder bed fusion

Kavas, Barış; Balta, Efe C.; Tucker, Michael; Rupenyan, Alisa; Lygeros, John; Bambach, Markus

doi:10.1016/j.addma.2023.103847

Please use this identifier to cite or link to this item: https://doi.org/10.21256/zhaw-29348

Publication type:	Article in scientific journal
Type of review:	Peer review (publication)
Title:	Layer-to-layer closed-loop feedback control application for inter-layer temperature stabilization in laser powder bed fusion
Authors:	Kavas, Barış Balta, Efe C. Tucker, Michael Rupenyan, Alisa Lygeros, John Bambach, Markus
et. al:	No
DOI:	10.1016/j.addma.2023.103847 10.21256/zhaw-29348
Published in:	Additive Manufacturing
Volume(Issue):	78
Issue:	103847
Issue Date:	Oct-2023
Publisher / Ed. Institution:	Elsevier
ISSN:	2214-7810 2214-8604
Language:	English
Subjects:	Laser powder bed fusion; Closed-loop feedback control; Layer-to-layer temperature control; Interlayer temperature stabilization
Subject (DDC):	670: Manufacturing
Abstract:	In laser powder bed fusion (LPBF), part quality and process conditions are highly dependent on the interlayer temperature (ILT) of the exposure surface of printed parts. State-of-the-art closed-loop control applications do not stabilize ILT, which has a decisive influence on the resulting part properties. This paper presents a closed-loop control strategy for LPBF that stabilizes the ILT. The thermal balance is defined with respect to exposure area change in overhanging parts and a control strategy is proposed to maintain the thermal balance by actuating energy input. The proposed control strategy uses an off-axis thermal camera for interlayer temperature acquisition to update the laser power layer to layer. An online optimization-based controller that leverages the repetitive nature of the LPBF process is implemented for the task. The developed controller is validated by experiments with different overhanging geometries. Successful ILT stabilization for various overhanging angles shows the robustness of the controller for an extended number of layers. However, modulation of laser power alone is shown to be insufficient to maintain the ILT within the stable processing window due to excessive heat accumulation in the long term. Nevertheless, the results of this study demonstrate the feasibility of ILT stabilization via of closed-loop control in LPBF and the potential for significant improvements in stabilizing the properties of the printed parts.
Further description:	The preprint version of this article was published on SSRN: https://papers.ssrn.com/sol3/papers.cfm?abstract_id=4496744.
URI:	https://digitalcollection.zhaw.ch/handle/11475/29348
Fulltext version:	Accepted version
License (according to publishing contract):	CC BY-NC-ND 4.0: Attribution - Non commercial - No derivatives 4.0 International
Restricted until:	2025-11-08
Departement:	School of Engineering
Organisational Unit:	Centre for Artificial Intelligence (CAI)
Appears in collections:	Publikationen School of Engineering

Files in This Item:

File	Description	Size	Format
2023_Kavas-etal_L2L-SLM-Temperature-Control_AM.pdf Until 2025-11-08	Accepted Version	4.62 MB	Adobe PDF	View/Open

Show full item record

Kavas, B., Balta, E. C., Tucker, M., Rupenyan, A., Lygeros, J., & Bambach, M. (2023). Layer-to-layer closed-loop feedback control application for inter-layer temperature stabilization in laser powder bed fusion. Additive Manufacturing, 78(103847). https://doi.org/10.1016/j.addma.2023.103847

Kavas, B. et al. (2023) ‘Layer-to-layer closed-loop feedback control application for inter-layer temperature stabilization in laser powder bed fusion’, Additive Manufacturing, 78(103847). Available at: https://doi.org/10.1016/j.addma.2023.103847.

B. Kavas, E. C. Balta, M. Tucker, A. Rupenyan, J. Lygeros, and M. Bambach, “Layer-to-layer closed-loop feedback control application for inter-layer temperature stabilization in laser powder bed fusion,” Additive Manufacturing, vol. 78, no. 103847, Oct. 2023, doi: 10.1016/j.addma.2023.103847.

KAVAS, Barış, Efe C. BALTA, Michael TUCKER, Alisa RUPENYAN, John LYGEROS und Markus BAMBACH, 2023. Layer-to-layer closed-loop feedback control application for inter-layer temperature stabilization in laser powder bed fusion. Additive Manufacturing. Oktober 2023. Bd. 78, Nr. 103847. DOI 10.1016/j.addma.2023.103847

Kavas, Barış, Efe C. Balta, Michael Tucker, Alisa Rupenyan, John Lygeros, and Markus Bambach. 2023. “Layer-to-Layer Closed-Loop Feedback Control Application for Inter-Layer Temperature Stabilization in Laser Powder Bed Fusion.” Additive Manufacturing 78 (103847). https://doi.org/10.1016/j.addma.2023.103847.

Kavas, Barış, et al. “Layer-to-Layer Closed-Loop Feedback Control Application for Inter-Layer Temperature Stabilization in Laser Powder Bed Fusion.” Additive Manufacturing, vol. 78, no. 103847, Oct. 2023, https://doi.org/10.1016/j.addma.2023.103847.