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<p>Thermal accumulation in the laser powder bed fusion (LPBF) additive manufacturing (AM) process is inherent from repeated heating of previously deposited layers. It can impact final part quality, microstructure, dimensional accuracy, and residual stresses in as-printed components. However, obtaining these temperatures can be cumbersome since each component being fabricated experiences varying laser exposure and cooling times. Since interlayer time also varies between each layer where multiple parts on a build plate contain different cross-sectional areas, it is difficult to pinpoint an exact thermal history of a single component within a single build plate. The purpose of this work is to introduce a process for determining the end-of-cycle (EOC) temperatures using image data to observe the manufacturing process from new layer detection, lasing process, and recoater actions using standard deviation values in each produced image frame. This method quantifies the layer-by-layer process LPBF manufacturing and can be used to obtain complete thermal history of components at each layer level. Results demonstrate that the proposed method is able to accurately determine the number of layers in a build, enabling the layer-wise reconstruction of the complete thermal history which is not achievable with machine reports alone. Furthermore, EOC temperature collection resulted in a 1.19% difference in symmetric error when compared to another method from literature, validating the process and thermal data for subsequent investigation.</p>

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End-of-cycle temperature determination and thermal history composition in laser powder bed fusion metal additive manufacturing

  • 期刊论文

  • 发表日期：

    2026年2月21日

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  • Emmanuel De Leon,
  • Alex Riensche,
  • Zahed Siddique,
  • Yingtao Liu

摘要

Thermal accumulation in the laser powder bed fusion (LPBF) additive manufacturing (AM) process is inherent from repeated heating of previously deposited layers. It can impact final part quality, microstructure, dimensional accuracy, and residual stresses in as-printed components. However, obtaining these temperatures can be cumbersome since each component being fabricated experiences varying laser exposure and cooling times. Since interlayer time also varies between each layer where multiple parts on a build plate contain different cross-sectional areas, it is difficult to pinpoint an exact thermal history of a single component within a single build plate. The purpose of this work is to introduce a process for determining the end-of-cycle (EOC) temperatures using image data to observe the manufacturing process from new layer detection, lasing process, and recoater actions using standard deviation values in each produced image frame. This method quantifies the layer-by-layer process LPBF manufacturing and can be used to obtain complete thermal history of components at each layer level. Results demonstrate that the proposed method is able to accurately determine the number of layers in a build, enabling the layer-wise reconstruction of the complete thermal history which is not achievable with machine reports alone. Furthermore, EOC temperature collection resulted in a 1.19% difference in symmetric error when compared to another method from literature, validating the process and thermal data for subsequent investigation.