There has been continuing effort in developing analytical, numerical, and empirical models of laser-based additive manufacturing (AM) processes in the literature. However, advanced physics-based models that can be directly used for feedback control design, i.e., control-oriented models, are severely lacking. In this paper, we develop a physics-based multivariable model for directed energy deposition. One important difference between our model from the existing work lies in a novel parameterization of the material transfer rate in the deposition as a function of the process operating parameters. Such parameterization allows an improved characterization of the steady-state melt-pool geometry compared to the existing lumped-parameter models. Predictions of melt-pool geometry and temperature from our model are validated using experimental data obtained from deposition of Ti-6AL-4V and deposition of Inconel® 718 on a laser engineering net shaping (LENS) AM process and finite-element analysis. Then based on this multivariable model, we design a nonlinear multi-input multi-output (MIMO) control, specifically a feedback linearization (FL) control, to track both melt-pool height and temperature reference trajectories using laser power and laser scan speed.
Physics-Based Multivariable Modeling and Feedback Linearization Control of Melt-Pool Geometry and Temperature in Directed Energy Deposition
The Pennsylvania State University,
University Park, PA 16802;
Manuscript received December 18, 2015; final manuscript received July 12, 2016; published online September 21, 2016. Assoc. Editor: Z. J. Pei.
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Wang, Q., Li, J., Gouge, M., Nassar, A. R., (Pan) Michaleris, P., and Reutzel, E. W. (September 21, 2016). "Physics-Based Multivariable Modeling and Feedback Linearization Control of Melt-Pool Geometry and Temperature in Directed Energy Deposition." ASME. J. Manuf. Sci. Eng. February 2017; 139(2): 021013. https://doi.org/10.1115/1.4034304
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