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<p>Laser powder bed fusion of metals (LPBFM) is an additive manufacturing process in which powdered alloy is selectively fused together to form near net shape parts. A method is proposed which optimizes parameters for the thermal conduction process window to omit lack of fusion defects. The approach takes into account: material, geometry, and previously experimentally derived robust process parameters. It entails experiments to calibrate and qualify the model to enable fine-tuning of process parameters for laser scan vectors to compensate for changing boundary conditions throughout the build. The objective is to satisfy defined adhesion conditions for the solidified melt tracks of each laser scan vector. The method transforms the build job preparation of LPBFM into an optimization problem. The required precision of model result is calculated based on adhesion conditions for the melt tracks and requirements derived for manufacturing model usage on the shop floor. The work contributes to a model-based quality assurance of LPBFM technology.</p>

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Optimization of thermal conduction welding parameters in LPBFM for enhanced adhesion control

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年2月19日

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  • Joshua Simon,
  • Tobias Redlich,
  • Jens-Peter Wulfsberg

摘要

Laser powder bed fusion of metals (LPBFM) is an additive manufacturing process in which powdered alloy is selectively fused together to form near net shape parts. A method is proposed which optimizes parameters for the thermal conduction process window to omit lack of fusion defects. The approach takes into account: material, geometry, and previously experimentally derived robust process parameters. It entails experiments to calibrate and qualify the model to enable fine-tuning of process parameters for laser scan vectors to compensate for changing boundary conditions throughout the build. The objective is to satisfy defined adhesion conditions for the solidified melt tracks of each laser scan vector. The method transforms the build job preparation of LPBFM into an optimization problem. The required precision of model result is calculated based on adhesion conditions for the melt tracks and requirements derived for manufacturing model usage on the shop floor. The work contributes to a model-based quality assurance of LPBFM technology.