research-article
Authors: P. Álvarez, F. Cordovilla, M.A. Montealegre, M. Díaz, + 4, S. Chacón-Fernández, A. García-Beltrán, I. Angulo, and J.L. Ocaña (Less)
Volume 236, Issue C
Published: 18 July 2024 Publication History
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Abstract
In the Directed Energy Deposition (DED) process, when the mass flow of metal particles is relatively high, the thickness of the layers increases, leading to a more productive process. The higher the mass flow is, the more difficult it becomes to get a stable melt pool. The accumulation of residual heat in the previously consolidated material constitutes a thermal input affecting the balance at the laser-material interaction zone. An accurate control of the temperature of the laser-material interaction zone is critical to maintain the dynamic viscosity of the liquid metal within the narrow margin in which it can be managed in a stable way. The present work introduces a thermal model in which domains with tunable properties are considered to reproduce the growing of the manufactured sample. Concurrently, a virtual closed-loop PID regulator has been implemented in order to calculate suitable values of laser power to compensate the heat accumulated in the material, offering the results from the model as input process parameters to be directly applied in the real process. The levels of laser power proposed by the model have been experimentally applied, leading to a stable process capable of carrying out in reality the desired component.
Highlights
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DED process with high mass flow constitutes a challenge in terms of process control.
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A new model with dynamic tunable domains and a virtual regulator is proposed.
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The model predicts the level of laser power to maintain stable the process at any time.
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Process parameters obtained with the model have been empirically applied with successful results.
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Published In
Finite Elements in Analysis and Design Volume 236, Issue C
Sep 2024
213 pages
ISSN:0168-874X
Issue’s Table of Contents
The Authors.
Publisher
Elsevier Science Publishers B. V.
Netherlands
Publication History
Published: 18 July 2024
Author Tags
- Additive-manufacturing
- Directed-energy-deposition
- Thermal-modeling
- Virtual control
- Steel AISI 316L
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