Additive manufacturing with metal is one of the most demanding areas of industrial production. Laser powder bed fusion (PBF) in particular enables complex geometries and dense components, but places high demands on process control and material understanding. A research team at the Swiss Empa is working on reducing these hurdles with the help of machine learning.
The work focuses on the dynamic interactions between the laser beam and metal powder. These depend heavily on process parameters such as laser power, scanning speed and powder properties. Two processing modes – pure melting in conduction mode and partial vaporization in keyhole mode – offer different advantages and disadvantages. The transition between the two depends on the material and is difficult to determine precisely.
“To ensure that laser-based processes can be used flexibly and achieve consistent results, we are working on better understanding, monitoring and control of these processes,” says Elia Iseli, research group leader in Empa’s Advanced Materials Processing laboratory in Thun.
A second research focus concerns laser beam welding. Here, the team is able to evaluate process data in real time using so-called FPGAs (field-programmable gate arrays) and make adaptive corrections during the welding process. This is intended to increase process reliability, particularly in the event of unforeseen faults, such as those caused by surface irregularities. “We hope that our algorithm will enable non-experts to use PBF devices,” summarizes Masinelli.
In the long term, the researchers are aiming to integrate the developed models into industrial control systems. The aim is to make PBF systems accessible to smaller companies too – with less effort, more reliable quality and reduced dependence on expert systems. “It is currently not possible to influence the welding process in real time,” says Chang Rajani. “This is beyond the capabilities of human experts.”
In the long term, the researchers are aiming to integrate the developed models into industrial control systems. The aim is to make PBF systems accessible to smaller companies too – with less effort, more reliable quality and reduced dependence on expert systems.
Metal Binder Jetting: The Key to Efficient Tool Manufacturing? - Exclusive Insights from INDO-MIM
Fill out the form and get instant access to an exclusive webinar on HP's Metal Binder Jetting 3D printing technology with exciting insights from INDO-MIM.Subscribe to our Newsletter
3DPresso is a weekly newsletter that links to the most exciting global stories from the 3D printing and additive manufacturing industry.
