Review on adaptive control of laser-directed energy deposition

Wang, Hao; Liu, Weiwei; Tang, Zijue; Wang, Yiwen; Mei, Xiaolei; Saleheen, Kazi Mojtaba; Wang, Zhenqiu; Zhang, Hongchao

doi:10.1117/1.oe.59.7.070901

Cited by 31 publications

(8 citation statements)

References 114 publications

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“…Geometric and temperature signatures are one of the most monitored aspects to avoid geometric distortions during the build which can even be extended to control the mechanical properties of the final build part. Thus, in situ monitoring and adaptive control enables the repeatability of DED [16].…”

Section: Introductionmentioning

confidence: 99%

Fabrication of Thin Walls with and without Close Loop Control as a Function of Scan Strategy Via Direct Energy Deposition

Ali

Tomesani

Ascari

et al. 2022

Lasers Manuf. Mater. Process.

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Direct Energy Deposition (DED) is a technique used to fabricate metallic parts and is a subcategory of metal additive manufacturing. Despite of its vast advantages over traditional manufacturing the deployment at industrial level is still limited due to underlaying concerns of process stability and repeatability. In-situ monitoring, therefore, is indispensable while depositing via DED. The present experiment is a step towards enhancing our current understanding of the DED when coupled with a closed loop control system to control melt pool width for deposition of thin-walled structures, and as a function of scan strategy. 316L stainless steel powder was deposited on S235JR substrate. A total of 6 iterations are reported, out of many performed, of which 3 were without the closed loop control. Also, to understand the effect of scan strategy as a function of laser power. Two different scan strategies were employed for understanding of the issue i.e., unidirectional, and bidirectional. Apart from the geometrical consistency of the wall, microhardness, density calculations and microstructure were investigated. The geometric consistency was found to be almost perfect with the bidirectional scan strategy. In case of unidirectional scan strategy, the wall shows a negative slope along the other extreme regardless of the closed loop control system. Dilution zone shows the hardness greater than both the substrate and the wall. The specimens fabricated without the use of closed loop control were found to be denser than their counterparts. This was found to be true also in case of manual reduction of power during each layer.

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Section: Introductionmentioning

confidence: 99%

Fabrication of Thin Walls with and without Close Loop Control as a Function of Scan Strategy Via Direct Energy Deposition

Ali

Tomesani

Ascari

et al. 2022

Lasers Manuf. Mater. Process.

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“…1, LMD uses laser power as a heat source to melt the substrate, and the raw materials are fed into the molten pool in the form of metal wire or powder. A single track is formed with the movement of the laser beam, and then a 3D part is formed as this movement is continued layer upon layer [2,3]. LMD is superior to traditional technologies in terms of geometric freedom, production flexibility, and low thermal input; thus, it has attracted considerable attention in the fields of aerospace, aviation, and mold as an effective and efficient process to fabricate metal and cladding parts and repair and refurbish damaged parts [4,5].…”

Section: Introductionmentioning

confidence: 99%

Impact of Pulsed Laser Parameters and Scanning Pattern on the Properties of Thin-Walled Parts Manufactured Using Laser Metal Deposition

et al. 2022

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The quality of parts manufactured using laser metal deposition (LMD), similar to other additive manufacturing methods, is influenced by processing parameters. Such parameters determine geometric stability, favorable microstructures, and good mechanical properties. This study aimed to investigate the effects of pulsed laser parameters (duty cycle and pulse frequency) and scanning patterns (unidirectional and bidirectional patterns) on the properties of parts fabricated using LMD. Results show that the properties of the LMD-fabricated parts are obviously influenced by pulsed laser parameters and scanning patterns. Using the unidirectional scanning pattern in both pulsed laser parameters enhances the properties of the thin-walled parts prepared using LMD. An increase in duty cycle can improve geometric stability, increase grain size, and reduce microhardness. Furthermore, the geometric stability does not vary considerably with the use of different frequencies, but the microstructure of fabricated parts shows various grain sizes with different pulse frequencies. In addition, the microhardness increases as the frequency increases from 13.33 to 50 Hz. In general, the influence of the duty cycle on geometric properties is greater than that of frequency. Meanwhile, the impact of frequency on microhardness is greater than that of the duty cycle.

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“…This technology is based on the discrete + accumulation molding method; it breaks the traditional subtractive manufacturing processing method by combining surface repair technology and rapid prototyping manufacturing technology to achieve highprecision layered processing components. 19 LAM also has some application problems. During the LAM process, the heating and cooling rates are very fast.…”

Section: Introductionmentioning

confidence: 99%

Review on scanning pattern evaluation in laser-based additive manufacturing

et al. 2021

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Laser-based additive manufacturing (LBAM) is a group of advanced manufacturing processes used to produce metal components and functionally graded products. Production in LBAM is either limited to the formation of thin or thick coatings on a substrate by laser metal deposition or the production of a fully functional metallic product by selective laser melting. In every case, LBAM fabricated components require optimization for the process parameters to avoid defects, such as porosity, crack holes, thermal deformation, and mechanical strength. As a key link in the laser additive manufacturing (LAM) process, laser scanning path planning is an effective strategy for balancing the temperature field of the formed part, avoiding stress concentration, and preventing deformation and cracking. Efficient, accurate, and reasonable planning of the laser scanning path is of great significance for improving the processing efficiency of the process data, prolonging the life of the laser scanning system, and improving the forming quality of the specimen. Through many studies, it was found that the scanning pattern of the lasers has a significant impact on the mechanical properties and deformations caused by a thermal mismatch during the process. Therefore, it is essential to have indepth knowledge about path planning in LBAM. Our review mainly focuses on the influence of scanning patterns on deformation, temperature, and mechanical properties in LBAM. Finally, our paper discusses the current study limitations and some future studies in LAM technology.

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Review on adaptive control of laser-directed energy deposition

Cited by 31 publications

References 114 publications

Fabrication of Thin Walls with and without Close Loop Control as a Function of Scan Strategy Via Direct Energy Deposition

Fabrication of Thin Walls with and without Close Loop Control as a Function of Scan Strategy Via Direct Energy Deposition

Impact of Pulsed Laser Parameters and Scanning Pattern on the Properties of Thin-Walled Parts Manufactured Using Laser Metal Deposition

Review on scanning pattern evaluation in laser-based additive manufacturing

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