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In situ measurement and closed-loop control for powder supply processes: Retrofittable solution in the context of laser metal deposition
Technische Universität Berlin, Coating Technology, Straße des 17. Juni 135, 10623, Berlin, Germany; Siemens AG, Otto-Hahn-Ring 6, 81739, Munich, Germany.
Luleå University of Technology, Department of Engineering Sciences and Mathematics, Product and Production Development. Siemens AG, Otto-Hahn-Ring 6, 81739, Munich, Germany.ORCID iD: 0000-0002-3403-5602
Siemens AG, Otto-Hahn-Ring 6, 81739, Munich, Germany.
Siemens AG, Otto-Hahn-Ring 6, 81739, Munich, Germany; Institute of Solid State Physics, TU Vienna, Wiedner Hauptstr. 8-10, 1040, Vienna, Austria.
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2021 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 116, no 3-4, p. 889-903Article in journal (Refereed) Published
Abstract [en]

The powder mass flow rate is one of the main parameters regarding the geometrical precision of built components in the additive manufacturing process of laser metal deposition. However, its accuracy, constancy, and repeatability over the course of the running process is not given. Reasons among others are the performance of the powder conveyors, the complex nature of the powder behavior, and the resulting issues with existing closed-loop control approaches. Additionally, a direct in situ measurement of the powder mass flow rate is only possible with intrusive methods. This publication introduces a novel approach to measure the current powder mass flow rate at a frequency of 125 Hz. The volumetric powder flow evaluation given by a simple optical sensor concept was transferred to a mass flow rate through mathematical dependencies. They were found experimentally for a nickel-based powder (Inconel 625) and are valid for a wide range of mass flow rates. With this, the dynamic behavior of a vibration powder feeder was investigated and a memory effect dependent on previous powder feeder speeds was discovered. Next, a closed-loop control with the received sensor signal was implemented. The concept as a whole gives a repeatable and accurate powder mass flow rate while being universally retrofittable and applicable. In a final step, the improved dynamic and steady performance of the powder mass flow rate with closed-loop control was validated. It showed a reduction of mean relative errors for step responses of up to 81% compared to the uncontrolled cases.

Place, publisher, year, edition, pages
Springer, 2021. Vol. 116, no 3-4, p. 889-903
Keywords [en]
Additive manufacturing, Laser metal deposition, Powder, Powder measurement, Mass flow rate
National Category
Manufacturing, Surface and Joining Technology
Research subject
Manufacturing Systems Engineering
Identifiers
URN: urn:nbn:se:ltu:diva-86482DOI: 10.1007/s00170-021-07438-zISI: 000665809000009Scopus ID: 2-s2.0-85112623859OAI: oai:DiVA.org:ltu-86482DiVA, id: diva2:1582070
Note

Validerad;2021;Nivå 2;2021-08-13 (alebob)

Available from: 2021-07-28 Created: 2021-07-28 Last updated: 2021-08-31Bibliographically approved

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Hauser, Tobias

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