Thermal modeling in metal additive manufacturing using graph theory: Experimental validation with in-situ infrared thermography data from laser powder bed fusion

Reza Yavari, Richard Williams, Kevin Cole, Paul Hooper, Prahalada Rao

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

The objective of this work is to provide experimental validation of the graph theory approach for predicting the thermal history in additively manufactured parts that was recently published in the ASME transactions. In the present paper the graph theory approach is validated with in-situ infrared thermography data in the context of the laser powder bed fusion (LPBF) additive manufacturing process. We realize this objective through the following three tasks. First, two types of test parts (stainless steel) are made in two corresponding build cycles on a Renishaw AM250 LPBF machine. The intent of both builds is to influence the thermal history of the part by changing the cooling time between melting of successive layers, called interlayer cooling time. Second, layer-wise thermal images of the top surface of the part are acquired using an in-situ a priori calibrated infrared camera. Third, the thermal imaging data obtained during the two builds were used to validate the graph theory-predicted surface temperature trends. Furthermore, the surface temperature trends predicted using graph theory are compared with results from finite element analysis. As an example, for one the builds, the graph theory approach accurately predicted the surface temperature trends to within 6% mean absolute percentage error, and approximately 14 Kelvin root mean squared error of the experimental data. Moreover, using the graph theory approach the temperature trends were predicted in less than 26 minutes which is well within the actual build time of 171 minutes.

Original languageEnglish (US)
Title of host publicationAdditive Manufacturing; Advanced Materials Manufacturing; Biomanufacturing; Life Cycle Engineering; Manufacturing Equipment and Automation
PublisherAmerican Society of Mechanical Engineers
ISBN (Electronic)9780791884256
DOIs
StatePublished - 2020
EventASME 2020 15th International Manufacturing Science and Engineering Conference, MSEC 2020 - Virtual, Online
Duration: Sep 3 2020 → …

Publication series

NameASME 2020 15th International Manufacturing Science and Engineering Conference, MSEC 2020
Volume1

Conference

ConferenceASME 2020 15th International Manufacturing Science and Engineering Conference, MSEC 2020
CityVirtual, Online
Period9/3/20 → …

Keywords

  • Additive manufacturing
  • Graph theory
  • Infrared thermal measurements
  • Interlayer cooling time
  • Laser powder bed fusion
  • Thermal modeling
  • Validation

ASJC Scopus subject areas

  • Safety, Risk, Reliability and Quality
  • Materials Science (miscellaneous)
  • Control and Optimization
  • Industrial and Manufacturing Engineering
  • Mechanical Engineering

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