研究目的
Investigating the use of iterative learning control (ILC) for laser power profile shaping in selective laser melting (SLM) to improve part quality.
研究成果
The study demonstrates that iterative learning control (ILC) can be effectively used to adjust the laser power profile in SLM based on melt pool emission measurements, thereby improving the uniformity of the process signature. The approach circumvents the need for a detailed process model and shows promise for real-time SLM process control. Future work will focus on generalizing the power input profile for non-repeating layer geometries and investigating the sensitivity to initial conditions.
研究不足
The study is limited by the high-frequency fluctuations in the coaxial signature, which can lead to noisy power profiles. Additionally, the applicability of the approach to whole builds with non-repeating layer geometries and varying initial conditions requires further investigation.
1：Experimental Design and Method Selection:
The study employs an open-source SLM printer for on-the-fly power adjustment and uses iterative learning control (ILC) to adjust the laser power profile based on melt pool emission measurements from a coaxial camera.
2：Sample Selection and Data Sources:
The experiments are conducted on an in-house built open-source SLM machine, with data collected from a coaxial camera observing the melt pool area.
3：List of Experimental Equipment and Materials:
Includes a laser, beam expander, scanner, focusing lens, off-axis and coaxial imaging systems, and a motion controller.
4：Experimental Procedures and Operational Workflow:
The laser scans a predefined trajectory on a powder bed, with power adjusted based on ILC updates derived from coaxial camera measurements.
5：Data Analysis Methods:
The effectiveness of the ILC approach is evaluated by analyzing the melt pool emission measurements and the resulting part quality.
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Focusing lens
S4LFT1420
Sill Optics
Focuses the laser beam onto the build plate.
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Off-axis imaging
A320
FLIR
Observes the whole build area for in-situ process monitoring.
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Coaxial imaging
DCC3240N
Thorlabs
Observes the melt pool area through the laser focusing optics.
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Scanner controller
RTC5 PCI control board
SCANLAB
Controls the scanner for precise laser beam positioning.
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Laser
1070 nm
IPG Photonics
Used to melt and fuse metal powder in the SLM process.
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Beam expander
S6EZM5076/328
Sill Optics
Widens the laser beam for focusing into a smaller spot on the build plate.
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Scanner
intelliSCANde 20
SCANLAB
Directs the laser beam to precise locations on the build plate.
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Motion controller
DMC-4080
Galil
Controls the movement of the build plate and powder delivery system.
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