A state-space model-based temperature control system for laser remanufacturing molten pool

References

• Adam, G. O. A., and D. Zimmer. 2014. “Design for Additive Manufacturing—Element Transitions and Aggregated Structures.” CIRP Journal of Manufacturing Science and Technology 7 (1): 20–28. https://doi.org/10.1016/j.cirpj.2013.10.001.
   Google Scholar
• Bernauer, C., A. Zapata, and M. F. Zaeh. 2022. “Toward Defect-Free Components in Laser Metal Deposition with Coaxial Wire Feeding Through Closed-Loop Control of the Melt Pool Temperature.” Journal of Laser Applications 34 (4): 042044. https://doi.org/10.2351/7.0000773.
   Web of Science ®Google Scholar
• Bourell, D. L., T. J. Watt, D. K. Leigh, and B. Fulcher. 2014. “Performance Limitations in Polymer Laser Sintering.” Physics Procedia 56:147–156. https://doi.org/10.1016/j.phpro.2014.08.157.
   Google Scholar
• Chan, Y. F., C. J. Chen, and M. Zhang. 2019. “Review of On-Line Monitoring Research on Metal Additive Manufacturing Process.” Materials Review 33 (17): 2839–2846+2867.
   Google Scholar
• Cheng, B., J. Lydon, K. Cooper, V. Cole, P. Northrop, and K. Chou. 2018. “Melt Pool Sensing and Size Analysis in Laser Powder-Bed Metal Additive Manufacturing.” Journal of Manufacturing Processes 32:744–753. https://doi.org/10.1016/j.jmapro.2018.04.002.
   Web of Science ®Google Scholar
• Chen, C. R., Y. Wang, H. G. Ou, Y. He, and X. Z. Tang. 2014. “A Review on Remanufacture of Dies and Moulds.” Journal of Cleaner Production 64:13–23. https://doi.org/10.1016/j.jclepro.2013.09.014.
   Web of Science ®Google Scholar
• Devesse, W., D. De Baere, M. Hinderdael, and P. Guillaume. 2016. “Hardware-In-The-Loop Control of Additive Manufacturing Processes Using Temperature Feedback.” Journal of Laser Applications 28 (2): 022302. https://doi.org/10.2351/1.4943911.
   Web of Science ®Google Scholar
• Devesse, W., D. De Baere, M. Hinderdael, and P. Guillaume. 2017. “Model-Based Temperature Feedback Control of Laser Cladding Using High-Resolution Hyperspectral Imaging.” IEEE/ASME Transactions on Mechatronics 22 (6): 2714–2722. https://doi.org/10.1109/tmech.2017.2754550.
   Web of Science ®Google Scholar
• Feng, W., Z. Z. Mao, Y. Yang, H. Ma, K. Zhao, C. Q. Qi, C. Hao, Z. W. Liu, H. M. Xie, and S. Liu. 2022. “Online Defect Detection Method and System Based on Similarity of the Temperature Field in the Melt Pool.” Additive Manufacturing 54:102760. https://doi.org/10.1016/j.addma.2022.102760.
   Web of Science ®Google Scholar
• Fotovvati, B., S. F. Wayne, G. Lewis, and E. Asadi. 2018. “A Review on Melt-Pool Characteristics in Laser Welding of Metals.” Advances in Materials Science and Engineering 2018:1–18. https://doi.org/10.1155/2018/4920718.
   Web of Science ®Google Scholar
• Gao, X., C. Shang, D. Huang, and F. Yang. 2017. “A Novel Approach to Monitoring and Maintenance of Industrial PID Controllers.” Control Engineering Practice 64: 111–126. https://doi.org/10.1016/j.conengprac.2017.04.008.
   Web of Science ®Google Scholar
• Griffith, M. L., M. E. Schlienger, L. D. Harwell, M. S. Oliver, M. D. Baldwin, M. T. Ensza, M. Essiena, J. Brooks, C. V. Robino, J. E. Smugeresky, W. H. Hofmeister, M. J. Wert, D. V. Nelson, et al. 1999. “Understanding Thermal Behavior in the LENS Process.” Materials & Design 20 (2–3): 107–113. https://doi.org/10.1016/S0261-3069(99)00016-3.
   Web of Science ®Google Scholar
• Hooper, P. A. 2018. “Melt Pool Temperature and Cooling Rates in Laser Powder Bed Fusion.” Additive Manufacturing 22:548–559. https://doi.org/10.1016/j.addma.2018.05.032.
   Web of Science ®Google Scholar
• Hossain, R. E. N., J. Lewis, and A. L. Moore. 2021. “In situ Infrared Temperature Sensing for Real-Time Defect Detection in Additive Manufacturing.” Additive Manufacturing 47:102328. https://doi.org/10.1016/j.addma.2021.102328.
   Web of Science ®Google Scholar
• Hua, T., C. Jing, L. Xin, F. Y. Zhang, and W. D. Huang. 2008. “Research on Molten Pool Temperature in the Process of Laser Rapid Forming.” Journal of Materials Processing Technology 198 (1–3): 454–462. https://doi.org/10.1016/j.jmatprotec.2007.06.090.
   Web of Science ®Google Scholar
• Huang, X. K., X. Y. Tian, Q. Zhong, S. W. He, C. B. Huo, Y. Cao, Z. Q. Tong, and D. C. Li. 2020. “Real-Time Process Control of Powder Bed Fusion by Monitoring Dynamic Temperature Field.” Advances in Manufacturing 8 (3): 380–391. https://doi.org/10.1007/s40436-020-00317-y.
   Web of Science ®Google Scholar
• Hussain, S. Z., Z. Kausar, Z. U. Koreshi, S. R. Sheikh, H. Z. U. Rehman, H. Yaqoob, M. F. Shah, A. Abdullah, and F. Sher. 2021. “Feedback Control of Melt Pool Area in Selective Laser Melting Additive Manufacturing Process.” Processes 9 (9): 1547. https://doi.org/10.3390/pr9091547.
   Web of Science ®Google Scholar
• Hu, D., C. S. Yu, and J. H. Yao. 2013. “Review of Laser Cladding Molten Pool Temperature Measurement and Control System.” Laser & Optoelectronics Progress 50 (12): 31–37.
   Google Scholar
• Köhler, H., C. Thomy, and F. Vollertsen. 2016. “Contact-Less Temperature Measurement and Control with Applications to Laser Cladding.” Welding in the World 60 (1): 1–9. https://doi.org/10.1007/s40194-015-0275-7.
   Web of Science ®Google Scholar
• Lee, C. M., W. S. Woo, and Y. H. Roh. 2017. “Remanufacturing: Trends and Issues.” International Journal of Precision Engineering and Manufacturing-Green Technology 4 (1): 113–125. https://doi.org/10.1007/s40684-017-0015-0.
   Web of Science ®Google Scholar
• Li, J. R., R. Jin, and H. Z. Yu. 2018. “Integration of Physically-Based and Data-Driven Approaches for Thermal Field Prediction in Additive Manufacturing.” Materials & Design 139:473–485. https://doi.org/10.1016/j.matdes.2017.11.028.
   Web of Science ®Google Scholar
• Li, Y. M., Z. X. Liu, H. O. Yang, X. Lin, W. D. Huang, and J. U. Li. 2003. “Measurement and Simulation of Temperature Field During Multi-Layer Laser Cladding.” Acta Metallurgica Sinica 5:521–525.
   Google Scholar
• Liu, W. W., Z. J. Tang, X. Y. Liu, H. J. Wang, and H. C. Zhang. 2017. “A Review on in-Situ Monitoring and Adaptive Control Technology for Laser Cladding Remanufacturing.” Procedia CIRP 61:235–240. https://doi.org/10.1016/j.procir.2016.11.217.
   Google Scholar
• Loucif, F., S. Kechida, and A. Sebbagh. 2019. “Whale Optimizer Algorithm to Tune PID Controller for the Trajectory Tracking Control of Robot Manipulator.” Journal of the Brazilian Society of Mechanical Sciences and Engineering 42 (1). https://doi.org/10.1007/s40430-019-2074-3.
   Web of Science ®Google Scholar
• Lu, K., W. Zhou, G. Zeng, and D. W. 2018. “Design of PID Controller Based on a Self-Adaptive State-Space Predictive Functional Control Using Extremal Optimization Method.” Journal of the Franklin Institute 355 (5): 2197–2220. https://doi.org/10.1016/j.jfranklin.2017.
   Web of Science ®Google Scholar
• Michaleris, P. 2014. “Modeling Metal Deposition in Heat Transfer Analyses of Additive Manufacturing Processes.” Finite Elements in Analysis and Design 86:51–60. https://doi.org/10.1016/j.finel.2014.04.003.
   Web of Science ®Google Scholar
• Oliveira, J. P., A. D. LaLonde, and J. Ma. 2020. “Processing Parameters in Laser Powder Bed Fusion Metal Additive Manufacturing.” Materials & Design 193:108762. https://doi.org/10.1016/j.matdes.2020.108762.
   Web of Science ®Google Scholar
• Rahito, W. D., and A. H. Azman. 2019. “Additive Manufacturing for Repair and Restoration in Remanufacturing: An Overview from Object Design and Systems Perspectives.” Processes 7 (11): 802. https://doi.org/10.3390/pr7110802.
   Web of Science ®Google Scholar
• Rezaeifar, H., and M. A. Elbestawi. 2021. “On-Line Melt Pool Temperature Control in L-PBF Additive Manufacturing.” The International Journal of Advanced Manufacturing Technology 112 (9–10): 2789–2804. https://doi.org/10.1007/s00170-020-06441-0.
   Web of Science ®Google Scholar
• Saboori, A., A. Aversa, G. Marchese, S. Biamino, M. Lombardi, and P. Fino. 2019. “Application of Directed Energy Deposition-Based Additive Manufacturing in Repair.” Applied Sciences 9 (16): 3316. https://doi.org/10.3390/app9163316.
   Google Scholar
• Shi, T., B. H. Lu, Z. Y. Wei, L. Zhou, and S. H. Shi. 2017. “Research of Closed-Loop Control of Deposition Height in Laser Metal Deposition.” Chinese Journal of Lasers 44 (7): 302–310. https://doi.org/10.3788/CJL201744.0702004.
   Google Scholar
• Tang, X. K., K. Y. Luo, and J. Z. Lu. 2021. “A New Method for Improving the Forming Quality in Laser Additive Manufacturing Process.” Materials Research Express 8 (2): 026523. https://doi.org/10.1088/2053-1591/abe659.
   Web of Science ®Google Scholar
• Xie, R. D., D. C. Li, B. Cui, L. Z. Zhang, and F. Gao. 2018. “A Defects Detection Method Based on Infrared Scanning in Laser Metal Deposition Process.” Rapid Prototyping Journal 24 (6): 945–954. https://doi.org/10.1108/RPJ-04-2017-0053.
   Web of Science ®Google Scholar
• Yuan, Y. H., Q. Yang, Z. H. Yan, X. L. Zhi, Z. J. Yuan, and X. D. Chen. 2018. “Research and Measurement of Surface Temperature Field in Laser Cladding Forming Molten Pool.” Laser & Infrared 48 (8): 985–992.
   Google Scholar
• Zeng, G. Q., J. Chen, M. R. Chen, Y. X. Dai, L. M. Li, K. D. Lu, and C. W. Zheng. 2015. “Design of Multivariable PID Controllers Using Real-Coded Population-Based Extremal Optimization.” Neurocomputing 151: 1343–1353. https://doi.org/10.1016/j.neucom.2014.10.
   Web of Science ®Google Scholar
• Zeng, G. Q., X. Q. Xie, M. R. Chen, and J. Weng. 2018. “Adaptive Population Extremal Optimization-Based PID Neural Network for Multivariable Nonlinear Control Systems.” Swarm and Evolutionary Computation 44: 320–334. https://doi.org/10.1016/j.swevo.2018.04.008.
   Web of Science ®Google Scholar
• Zhang, Z. Y., Z. C. Liu, and D. Z. Wu. 2016. “Prediction of Melt Pool Temperature in Directed Energy Deposition Using Machine Learning.” Additive Manufacturing 37:101692. https://doi.org/10.1016/j.addma.2020.101692.
   Google Scholar
• Zhong, Q., X. Y. Tian, X. K. Huang, C. B. Huo, and D. C. Li. 2021. “Using Feedback Control of Thermal History to Improve Quality Consistency of Parts Fabricated via Large-Scale Powder Bed Fusion.” Additive Manufacturing 42:101986. https://doi.org/10.1016/j.addma.2021.101986.
   Web of Science ®Google Scholar