Real-time process control of powder bed fusion by monitoring dynamic temperature field
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Real-time process control of powder bed fusion by monitoring dynamic temperature field Xiao-Kang Huang1 • Xiao-Yong Tian1 • Qi Zhong1 • Shun-Wen He1 Chun-Bao Huo1 • Yi Cao1 • Zhi-Qiang Tong1 • Di-Chen Li1
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Received: 26 November 2019 / Revised: 11 April 2020 / Accepted: 30 June 2020 Ó Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature 2020
Abstract This study aims to optimize the uniformity of the temperature field during sintering to improve part performance. A temperature-field monitoring system is established based on an infrared thermal imager and the temperature field data obtained during the sintering of a part can be measured in real time. The relationship among the sintering temperature field, sintering process parameters, and part performance is established experimentally. Subsequently, a temperature field monitoring and analysis system is constructed, and various sintering temperaturefield control strategies are established for various part sizes. Finally, a dynamic control strategy for controlling the temperature field during sintering is proposed, experimentally validated, and fully integrated into a developed powder bed fusion (PBF) equipment. For eight-shaped standard parts, the range of sintering temperature field is optimized from 44.1 °C to 19.7 °C, whereas the tensile strength of the parts increased by 15.4%. For large-size H parts, localized over burning is eliminated and the final quality of the part is optimized. This strategy is critical for the optimization of the PBF process for large-sized parts, in particular in the large-sized die manufacturing industry, which offers promise in the optimization of part performance. Keywords Powder bed fusion (PBF) Sintering temperature field Monitoring system Infrared thermal imager
& Xiao-Yong Tian [email protected] 1
State Key Laboratory of Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an 710049, People’s Republic of China
1 Introduction Powder bed fusion (PBF) is an additive manufacture process [1]. It is one of the most widely used additive manufacturing technologies [2, 3], as it can be used to easily process various materials into prototypes, including polymers, metals, and ceramics [4, 5]. Parts are created layerby-layer from powder material using heat generated from scanning laser in this process [6]. Generally, all powder materials that can be melted can be used in PBF processes [7]. Compared with traditional manufacturing processes, PBF processes offer short design-to-manufacture cycles, high geometrical freedom, and low production costs for small batch parts [8, 9]. However, PBF processes are accompanied by complicated heat transfer and significant temperature field changes [10]. The entire process is affected by multivariate parameters, including laser power, scanning speed, and hatch spacing. Different process parameters result in temperature field changes during the fusion process and hence, determine the final properties of the prepared components. Therefore, the monitoring and
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