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<p>Heterogeneous temperature distributions in additively manufactured metallic parts, particularly in laser powder bed fusion (PBF-LB/M), pose a major challenge to achieving high-quality components due to thermal distortions, microstructural inconsistencies, and shifts in the process window. This study introduces a physics-aware feedforward approach for regulating dwell time that effectively mitigates distortion in 3D-printed cantilevers by reducing thermal variations along the build direction. A fast, 1D finite volume method thermal simulation is employed to estimate the temperature profile throughout the build. The interlayer dwell time is dynamically adjusted based on a predefined thermal difference threshold between layers to minimize residual stresses and part deformation. Experimental validation on a cantilever beam geometry confirms that the adaptive dwell time strategy significantly reduces distortion compared to a constant dwell time approach. The proposed method enhances thermal stability while maintaining processing times, offering an efficient solution for distortion control in PBF-LB/M. These findings contribute to advancing process optimization strategies by integrating physics-based thermal modeling with feedforward control.</p>

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Physics-aware feedforward dwell time adjustment for mitigating distortion in additively manufactured cantilevers

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年7月30日

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  • Barış Kavas,
  • Lars Witte,
  • Efe C. Balta,
  • Michael R. Tucker,
  • Mohamadreza Afrasiabi,
  • Markus Bambach

摘要

Heterogeneous temperature distributions in additively manufactured metallic parts, particularly in laser powder bed fusion (PBF-LB/M), pose a major challenge to achieving high-quality components due to thermal distortions, microstructural inconsistencies, and shifts in the process window. This study introduces a physics-aware feedforward approach for regulating dwell time that effectively mitigates distortion in 3D-printed cantilevers by reducing thermal variations along the build direction. A fast, 1D finite volume method thermal simulation is employed to estimate the temperature profile throughout the build. The interlayer dwell time is dynamically adjusted based on a predefined thermal difference threshold between layers to minimize residual stresses and part deformation. Experimental validation on a cantilever beam geometry confirms that the adaptive dwell time strategy significantly reduces distortion compared to a constant dwell time approach. The proposed method enhances thermal stability while maintaining processing times, offering an efficient solution for distortion control in PBF-LB/M. These findings contribute to advancing process optimization strategies by integrating physics-based thermal modeling with feedforward control.