Flexible Automation and Intelligent Manufacturing 2024, Taiwan - Optimization of Thermal Induction Welding Parameters in LPBFM for Enhanced Adhesion Control

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 for qualifying a model to optimize thermal conduction welding parameters to omit lack of fusion defects is proposed. The approach takes into account: material, geometry and previously experimentally derived, robust process parameters.

It entails carrying out specific experiments to generate data for calibration and validation of the model for fine-tuning of process parameters to compensate for the changing boundary conditions throughout the build. The objective is to achieve defined adhesion criteria for the meltpools of each laser scan vector.

The method transforms the build job preparation of LPBFM into an optimization problem by determining the required precision and defining requirements for the model approach to be applicable on the shopfloor. The work contributes to a model-based quality assurance of LPBFM technology.