Model-Based Feedforward Control of Part Height in Directed Energy Deposition
Control of the geometric accuracy of a metal deposit is critical in the repair and fabrication of complex components through Directed Energy Deposition (DED). This paper developed and experimentally evaluated a model-based feedforward control of laser power with the objective of achieving the target...
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| Format: | Article |
| Language: | English |
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MDPI AG
2021-01-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/14/2/337 |
| _version_ | 1797413070601977856 |
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| author | Qian Wang Jianyi Li Abdalla R. Nassar Edward W. Reutzel Wesley F. Mitchell |
| author_facet | Qian Wang Jianyi Li Abdalla R. Nassar Edward W. Reutzel Wesley F. Mitchell |
| author_sort | Qian Wang |
| collection | DOAJ |
| description | Control of the geometric accuracy of a metal deposit is critical in the repair and fabrication of complex components through Directed Energy Deposition (DED). This paper developed and experimentally evaluated a model-based feedforward control of laser power with the objective of achieving the targeted part height in DED. Specifically, based on the dynamic model of melt-pool geometry derived from our prior work, a nonlinear inverse-dynamics controller was derived in a hatch-by-hatch, layer-by-layer manner to modulate the laser power such that the melt-pool height was regulated during the simulated build process. Then, the laser power trajectory from the simulated closed-loop control under the nonlinear inverse-dynamics controller was implemented as a feedforward control in an Optomec Laser-Engineered Net Shape (LENS) MR-7 system. This paper considered the deposition of L-shaped structures of Ti-6AL-4V as a case study to illustrate the proposed model-based controller. Experimental validation showed that by applying the proposed model-based feed-forward control for laser power, the resulting build had 24–42% reduction in the average build height error with respect to the target build height compared to applying a constant laser power through the entire build or applying a hatch-dependent laser power strategy, for which the laser power values were obtained from experimental trial and error. |
| first_indexed | 2024-03-09T05:12:15Z |
| format | Article |
| id | doaj.art-bab230133a9f499289637a662bd09d69 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-09T05:12:15Z |
| publishDate | 2021-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-bab230133a9f499289637a662bd09d692023-12-03T12:48:41ZengMDPI AGMaterials1996-19442021-01-0114233710.3390/ma14020337Model-Based Feedforward Control of Part Height in Directed Energy DepositionQian Wang0Jianyi Li1Abdalla R. Nassar2Edward W. Reutzel3Wesley F. Mitchell4Department of Mechanical Engineering, The Pennsylvania State University, University Park, PA 16802, USADepartment of Mechanical Engineering, The Pennsylvania State University, University Park, PA 16802, USAApplied Research Laboratory, The Pennsylvania State University, University Park, PA 16802, USAApplied Research Laboratory, The Pennsylvania State University, University Park, PA 16802, USAApplied Research Laboratory, The Pennsylvania State University, University Park, PA 16802, USAControl of the geometric accuracy of a metal deposit is critical in the repair and fabrication of complex components through Directed Energy Deposition (DED). This paper developed and experimentally evaluated a model-based feedforward control of laser power with the objective of achieving the targeted part height in DED. Specifically, based on the dynamic model of melt-pool geometry derived from our prior work, a nonlinear inverse-dynamics controller was derived in a hatch-by-hatch, layer-by-layer manner to modulate the laser power such that the melt-pool height was regulated during the simulated build process. Then, the laser power trajectory from the simulated closed-loop control under the nonlinear inverse-dynamics controller was implemented as a feedforward control in an Optomec Laser-Engineered Net Shape (LENS) MR-7 system. This paper considered the deposition of L-shaped structures of Ti-6AL-4V as a case study to illustrate the proposed model-based controller. Experimental validation showed that by applying the proposed model-based feed-forward control for laser power, the resulting build had 24–42% reduction in the average build height error with respect to the target build height compared to applying a constant laser power through the entire build or applying a hatch-dependent laser power strategy, for which the laser power values were obtained from experimental trial and error.https://www.mdpi.com/1996-1944/14/2/337directed energy depositionadditive manufacturingfeedforward controlnonlinear inverse-dynamics controlbuild height regulation |
| spellingShingle | Qian Wang Jianyi Li Abdalla R. Nassar Edward W. Reutzel Wesley F. Mitchell Model-Based Feedforward Control of Part Height in Directed Energy Deposition Materials directed energy deposition additive manufacturing feedforward control nonlinear inverse-dynamics control build height regulation |
| title | Model-Based Feedforward Control of Part Height in Directed Energy Deposition |
| title_full | Model-Based Feedforward Control of Part Height in Directed Energy Deposition |
| title_fullStr | Model-Based Feedforward Control of Part Height in Directed Energy Deposition |
| title_full_unstemmed | Model-Based Feedforward Control of Part Height in Directed Energy Deposition |
| title_short | Model-Based Feedforward Control of Part Height in Directed Energy Deposition |
| title_sort | model based feedforward control of part height in directed energy deposition |
| topic | directed energy deposition additive manufacturing feedforward control nonlinear inverse-dynamics control build height regulation |
| url | https://www.mdpi.com/1996-1944/14/2/337 |
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