Intelligent Additive Manufacturing Architecture for Enhancing Uniformity of Surface Roughness and Mechanical Properties of Laser Powder Bed Fusion Components
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- 最近更新: 2023-11-04, 週六 01:38
- 發佈: 2022-09-16, 週五 12:01
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Authors: Hong-Chuong Tran, Yu-Lung Lo, Haw-Ching Yang, Hung-Chang Hsiao, Fan-Tien Cheng, and Tsung-Han Kuo
Publication: IEEE Transactions on Automation Science and Engineering (TASE), Oct. 2023.
Abstract:
In the Laser Powder Bed Fusion (L-PBF) process, 3D components with complex geometries are fabricated in a layer-bylayer fashion by using a controlled laser beam to selectively melt particular regions of the metal powder bed. However, due to the stochastic nature of the L-PBF process, the top surface roughness of each solidified layer tends to be different even when the optimal processing conditions for the different positions on the build plate are employed. As a result, the mechanical properties of the built components frequently vary from one component to the next. Accordingly, this study proposes an Intelligent Additive Manufacturing Architecture (IAMA) for controlling the surface roughness of each build layer through an appropriate adjustment of the laser re-melting parameters. The IAMA architecture comprises five modules, namely In-Situ Metrology (ISM), Ex-Situ Metrology (ESM), Automatic Virtual Metrology (AVM), Additive Manufacturing Simulation (AMS) and Intelligent Compensator (IC). The feasibility of the proposed architecture is demonstrated by comparing the top surface roughness of cubic and tensile test samples built using the proposed method with those built using a traditional L-PBF approach without surface roughness control. It is found that the samples fabricated using the IAMA approach have an average top surface roughness of 1.6 µm and a standard deviation is 0.7 µm. By contrast, the samples produced using the traditional L-PBF approach have an average surface roughness of 13.45 µm and a standard deviation of 2.5 µm. In addition, the specimens produced with the assistance of IAMA architecture have an average tensile strength of 1013 MPA with a standard deviation of 69.5 MPa, while those printed without surface roughness control have an average tensile strength of 903 MPa with a standard deviation of 101.4 MPa.