Laser wire-feed metal additive manufacturing of the Al alloy

Huang, Wenhao; Chen, Shujun; Xiao, Jun Jun; Jiang, Xiaoqing; Jia, Yazhou

doi:10.1016/j.optlastec.2020.106627

Cited by 53 publications

(25 citation statements)

References 29 publications

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“…For all these cases the effect on the track height is much clearer than on the width. All these trends agree with observations in the literature [12,13]. Image a. in Fig.…”

Section: Results and Analysissupporting

confidence: 92%

Data-driven Process Parameter Optimisation for Laser Wire Metal Additive Manufacturing

Roberts

Xia

Kennedy

2022

2022 27th International Conference on Automation and Computing (ICAC)

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Laser Wire Additive manufacturing (LWAM) requires a clear understanding of process parameters and their effects on the geometry and wider material properties of the parts produced to support the production of consistent, repeatable quality parts. Furthermore, its ability to capitalise on using novel alloys depends on efficient characterisation of optimum process parameters. In this work, a method for identifying the range of usable parameters is presented, which produces sufficient data to train Cascade Forward Neural Networks, which are capable of predicting process windows and basic LWAM track geometries for 316L stainless steel. The performance of these networks provides the foundation for further work to identify optimum process parameters and, through transfer learning, may reduce the experimental requirements for the process development of other alloys.

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“…For all these cases the effect on the track height is much clearer than on the width. All these trends agree with observations in the literature [12,13]. Image a. in Fig.…”

Section: Results and Analysissupporting

confidence: 92%

Data-driven Process Parameter Optimisation for Laser Wire Metal Additive Manufacturing

Roberts

Xia

Kennedy

2022

2022 27th International Conference on Automation and Computing (ICAC)

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“…It was concluded that the laser spot size, the laser power, the wire speed, and the traverse speed have the strongest influence on the geometry of the deposition [19,25]. Further works studied the correlation between several of the mentioned process parameters and the dimensions of the bead through empirical or numerical models [26][27][28][29][30][31][32]. Although the identified correlations show similarities, comparisons and general conclusions are difficult to draw since different systems and parameter ranges were used.…”

Section: State Of the Art 121 Process Development For Lmd With Latera...mentioning

confidence: 99%

Investigation on the Cause-Effect Relationships between the Process Parameters and the Resulting Geometric Properties for Wire-Based Coaxial Laser Metal Deposition

Zapata

Bernauer

Stadter

et al. 2022

Metals

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Coaxial Laser Metal Deposition with wire (LMD-w) is a valuable complement to the already established Additive Manufacturing processes in production because it allows a direction-independent process with high deposition rates and high deposition accuracy. However, there is a lack of knowledge regarding the adjustment of the process parameters during process development to build defect-free parts. Therefore, in this work, a process development for coaxial LMD-w was conducted using an aluminum wire AlMg4,5MnZr and a stainless steel wire AISI 316L. At first, the boundaries for parameter combinations that led to a defect-free process were identified. The proportion between the process parameters energy per unit length and speed ratio proved crucial for a defect-free process. Then, the influence of the process parameters on the height and width of single beads for both materials was analyzed using a regression analysis. It was shown that linear models are suitable for describing the correlation between the process parameters and the dimensions of the beads. Lastly, a material-independent formula is presented to calculate the height increment per layer needed for an additive process. For future studies, the results of this work will be an aid for process development with different materials.

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“…According to different sources of energy used for metal deposition, M-AM could be classified into Arc Additive Manufacturing (AAM), Electron Beam Additive Manufacturing (EBAM), and Laser Additive Manufacturing (LAM) [8]. With regard to the additive material form, Laser Additive Manufacturing could be divided into powder-based and wire-based Laser Additive Manufacturing.…”

Section: Introductionmentioning

confidence: 99%

Modeling and Control of Layer Height in Laser Wire Additive Manufacturing

et al. 2022

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Laser Wire Additive Manufacturing (LWAM) is a flexible and fast manufacturing method used to produce variants of high metal geometric complexity. In this work, a physics-based model of the bead geometry including process parameters and material properties was developed for the LWAM process of large-scale products. The developed model aimed to include critical process parameters, material properties and thermal history to describe the relationship between the layer height with different process inputs (i.e., the power, the standoff distance, the temperature, the wire-feed rate, and the travel speed). Then, a Model Predictive Controller (MPC) was designed to keep the layer height trajectory constant taking into consideration the constraints faced in the LWAM technology. Experimental validation results were performed to check the accuracy of the proposed model and the results revealed that the developed model matches the experimental data. Finally, the designed MPC controller was able to track a predefined layer height reference signal by controlling the temperature input of the system.

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Laser wire-feed metal additive manufacturing of the Al alloy

Cited by 53 publications

References 29 publications

Data-driven Process Parameter Optimisation for Laser Wire Metal Additive Manufacturing

Data-driven Process Parameter Optimisation for Laser Wire Metal Additive Manufacturing

Investigation on the Cause-Effect Relationships between the Process Parameters and the Resulting Geometric Properties for Wire-Based Coaxial Laser Metal Deposition

Modeling and Control of Layer Height in Laser Wire Additive Manufacturing

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