Feedforward control of thermal history in laser powder bed fusion: Toward physics-based optimization of processing parameters

We developed and applied a model-driven feedforward control approach to mitigate thermal-induced flaw formation in laser powder bed fusion (LPBF) additive manufacturing process. The key idea was avert heat buildup LPBF part before it is printed by adapting process parameters layer-by-layer based on insights from physics-based thermal simulation model. motivation being replace cumbersome empirical parameter optimization with physics-guided strategy. consisted of three steps: prediction, analysis, correction. First, the temperature distribution predicted rapidly using graph theory-based computational Second, model-derived trends were analyzed isolate layers potential buildup. Third, affected corrected printing adjusting optimized through iterative simulations. effectiveness demonstrated experimentally two separate build plates. In first plate, termed fixed processing , ten different nickel alloy 718 parts produced under constant conditions. On second identical called controlled processing, power dwell time for each adjusted simulations avoid To validate model predictions, surface tracked calibrated infrared camera. Post-process examined non-destructive destructive materials characterization techniques. Compared showed superior geometric accuracy resolution, finer grain size, increased microhardness, reduced roughness.