研究目的
To develop a fast, scalable method for part-scale process optimization of arbitrary geometries in laser powder bed fusion additive manufacturing to reduce the time and cost of creating functional parts.
研究成果
The developed method enables part-scale parameter optimization of arbitrary geometries to be performed in a fast and targeted manner, facilitating knowledge transfer gained from solving one problem to other problems. The software produces an improved set of build files, reducing the number of iterations required to achieve certification quality on the first print.
研究不足
The study is limited by the computational complexity of part-scale simulation of the full manufacturing process and the need for high-performance computing infrastructure for high-fidelity physics simulations.
1:Experimental Design and Method Selection:
The study employs a computational framework for part-scale process optimization using feature extraction and simulation-based feed forward control models.
2:Sample Selection and Data Sources:
The method is applied to parts with complex features, and parts are printed on a customized open architecture LPBF machine.
3:List of Experimental Equipment and Materials:
A 400W laser (IPG Photonics) focused to a 100μm D4σ Gaussian beam diameter through a galvanometer scanner (Scanlabs), gas atomized stainless steel 316L powder, and a LabVIEW based machine controller.
4:Experimental Procedures and Operational Workflow:
The software generates optimized machine-agnostic build files, and parts are printed with adapted laser power and velocity for each laser strike.
5:Data Analysis Methods:
The results are analyzed by cross-sectioning and polishing the printed parts, followed by imaging for analysis.
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