Feed-Forward Controls for Laser Powder Bed Fusion Based Metal Additive Manufacturing

Previously developed hardware/software platform, in-situ sensing technology (thermal and laser line) and multi-scale multi-physics material model, will be integrated and expanded to produce a Feed Forwad Control (FFC) system for AM. The applicability of this framework for improving the quality of the build for qualification and certification process will be shown on simple and complex AM fabricated components. Terrain micro mapping and defect detection will be upgraded for user-friendliness. Customization of software and machine tool interface will expand technology to service multiple platforms. The innovation includes a) Real-Time Monitored Open Source AM System, b) Quality Data Analysis System for Monitoring Printing Defects and Anomalies, and c) Zeroth-Order-Model (ZOM) for Thermal Analysis. The overall objectives of the proposed program are three-fold: a) Enhancement of predictive software to detect lack-of-fusion using fast thermal analysis, b) Big data processing and visualization according to the sensor values to detect defects, abnormal process conditions, and melt pool characterization, and c) Closed-loop feedback control system with real time decision making algorithm.