Doctor of Philosophy, The Ohio State University, 2023, Mechanical Engineering
Metal Powder Bed Fusion (PBF) is a type of additive manufacturing process that incrementally builds parts by fusing 2D slices of the geometry into layers of metal powder, using either a laser (L-PBF) or electron beam (E-PBF), and is among the emerging technologies of Industry 4.0. The predominant quality control methods for PBF are pre- and post-process tests of the part and materials, which are inefficient because they cannot prematurely halt malfunctioning builds as errors occur. Live (In-situ) monitoring of the PBF process for defects, in which the defects are oftentimes due to improper thermal management, and in-situ control of the PBF process to ensure good thermal management, are areas of active research. These efforts are currently dominated by constructing data-driven PBF thermal models and using the corresponding estimations to judge the current thermal state (process monitoring) and to decide correction factors (process control). Collecting the data for training these methods is costly and renders them inflexible with respect to changes in part design and processing conditions, because they do not offer guaranteed performance in environments that lay outside the scope of the training data. Since PBF exists to increase production flexibility, lessening this dependency on training data is essential.
To address this challenge, we demonstrate the efficacy of applying training data-free algorithms to the in-situ PBF thermal process monitoring and control problems. Our process monitoring algorithm is the Ensemble Kalman Filter (EnKF), which is a type of state estimator that uses a particle swarm to generate self-tuned, approximately 2-norm optimal, model-based estimates of the relevant process signatures. Here, the signatures are all temperatures in the PBF build. Our control algorithm is Model Predictive Control (MPC), which uses model-based predictions of future process signatures (here, temperatures) to determine a sequence of process inputs that reg (open full item for complete abstract)
Committee: David Hoelzle (Advisor); Andrew Gillman (Committee Member); Andrea Serrani (Committee Member); Mrinal Kumar (Committee Member); Michael Groeber (Committee Member)
Subjects: Mechanical Engineering