A review of the multi-dimensional application of machine learning to improve the integrated intelligence of laser powder bed fusion

Li, K.; Ma, Ruijin; Yu, Qin; Gong, Na; Wu, Jinzhou; Wen, Peng; Tan, Susheng; Zhang, Zhengwen; Murr, Lawrence E.; Luo, Jun

doi:10.1016/j.jmatprotec.2023.118032

Cited by 28 publications

(5 citation statements)

References 124 publications

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“…However, the limitations of the traditional casting process in terms of the freedom to shape the part limits the designer’s creative freedom and the range of applications for the material. Laser powder bed fusion (LPBF) is a metal additive manufacturing technology that melts discrete powders materials and deposits them layer by layer [ 7 , 8 , 9 , 10 , 11 , 12 , 13 ]. The layer-by-layer forming feature of the powder bed enables the manufacture of parts with complex shapes [ 14 ], expanding the freedom of part design [ 15 , 16 , 17 , 18 , 19 ].…”

Section: Introductionmentioning

confidence: 99%

High-Quality Spherical Silver Alloy Powder for Laser Powder Bed Fusion Using Plasma Rotating Electrode Process

Li,

Zhang,

Chen

et al. 2024

Micromachines

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The plasma rotating electrode process (PREP) is an ideal method for the preparation of metal powders such as nickel-based, titanium-based, and iron-based alloys due to its low material loss and good degree of sphericity. However, the preparation of silver alloy powder by PREP remains challenging. The low hardness of the mould casting silver alloy leads to the bending of the electrode rod when subjected to high-speed rotation during PREP. The mould casting silver electrode rod can only be used in low-speed rotation, which has a negative effect on particle refinement. This study employed continuous casting (CC) to improve the surface hardness of S800 Ag (30.30% higher than mould casting), which enables a high rotation speed of up to 37,000 revolutions per minute, and silver alloy powder with an average sphericity of 0.98 (5.56% higher than gas atomisation) and a sphericity ratio of 97.67% (36.28% higher than gas atomisation) has been successfully prepared. The dense S800 Ag was successfully fabricated by laser powder bed fusion (LPBF), which proved the feasibility of preparing high-quality powder by the “CC + PREP” method. The samples fabricated by LPBF have a Vickers hardness of up to 271.20 HV (3.66 times that of mould casting), leading to a notable enhancement in the strength of S800 Ag. In comparison to GA, the S800 Ag powder prepared by “CC + PREP” exhibits greater sphericity, a higher sphericity ratio and less satellite powder, which lays the foundation for dense LPBF S800 Ag fabrication.

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Section: Introductionmentioning

confidence: 99%

High-Quality Spherical Silver Alloy Powder for Laser Powder Bed Fusion Using Plasma Rotating Electrode Process

Li,

Zhang,

Chen

et al. 2024

Micromachines

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“…Building on the work in the first edition [ 11 ] and sincere cooperation with the Guest Editors [ 12 ], the second edition will continue to concentrate on laser additive manufacturing, including macro- to micro-scale additive manufacturing with lasers, including structure design/material design [ 13 ], fabrication [ 14 ], modeling and simulation; in situ characterization of additive manufacturing processes [ 15 ]; and ex situ material characterization and performances [ 16 ], with an overview of various applications [ 17 ] in aerospace, biomedicine, optics, transportation, energy, etc.…”

Section: Introduction For Special Issue Of Laser Additive Manufacturingmentioning

confidence: 99%

Editorial for the Special Issue on Laser Additive Manufacturing: Design, Materials, Processes, and Applications, 2nd Edition

Yin,

Liu,

et al. 2024

Micromachines

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“…Nevertheless, an LPBF-created part can suffer several different types of defects (porosity, poor surface finish, cracking, etc.) due to processing parameter fluctuations or unstable processing conditions, which hinder its widespread application [ 6 , 7 ]. In recent years, in situ monitoring has emerged as an alternative accommodation for defect identification and control, which has become a research hot topic [ 8 ].…”

Section: Introductionmentioning

confidence: 99%

Monitoring of Single-Track Melting States Based on Photodiode Signal during Laser Powder Bed Fusion

Cao,

Hu,

Zhou

et al. 2023

Sensors

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Single track is the basis for the melt pool modeling and physics work in laser powder bed fusion (LPBF). The melting state of a single track is closely related to defects such as porosity, lack of fusion, and balling, which have a significant impact on the mechanical properties of an LPBF-created part. To ensure the reliability of part quality and repeatability, process monitoring and feedback control are emerging to improve the melting states, which is becoming a hot topic in both the industrial and academic communities. In this research, a simple and low-cost off-axial photodiode signal monitoring system was established to monitor the melting pools of single tracks. Nine groups of single-track experiments with different process parameter combinations were carried out four times and then thirty-six LPBF tracks were obtained. The melting states were classified into three classes according to the morphologies of the tracks. A convolutional neural network (CNN) model was developed to extract the characteristics and identify the melting states. The raw one-dimensional photodiode signal data were converted into two-dimensional grayscale images. The average identification accuracy reached 95.81% and the computation time was 15 ms for each sample, which was promising for engineering applications. Compared with some classic deep learning models, the proposed CNN could distinguish the melting states with higher classification accuracy and efficiency. This work contributes to real-time multiple-sensor monitoring and feedback control.

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A review of the multi-dimensional application of machine learning to improve the integrated intelligence of laser powder bed fusion

Cited by 28 publications

References 124 publications

High-Quality Spherical Silver Alloy Powder for Laser Powder Bed Fusion Using Plasma Rotating Electrode Process

High-Quality Spherical Silver Alloy Powder for Laser Powder Bed Fusion Using Plasma Rotating Electrode Process

Editorial for the Special Issue on Laser Additive Manufacturing: Design, Materials, Processes, and Applications, 2nd Edition

Monitoring of Single-Track Melting States Based on Photodiode Signal during Laser Powder Bed Fusion

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