Methods of optimizing 3-D printing parameters for metallic materials
Inventors
Elwany, Alaa • Karaman, Ibrahim • Arroyave, Raymundo • Seede, Raiyan • Zhang, Bing • Johnson, Luke
Assignees
Interested in licensing this patent?
MTEC can help explore whether this patent might be available for licensing for your application.
Publication Number
US-12454005-B2
Publication Date
2025-10-28
Expiration Date
Abstract
A method for determining alloy processing parameters is provided. Simulated melt pool temperature and melt pool geometries can be used to create an initial printability map based on laser speed and laser power, and the printability map can include regions with potential manufacturing defects. Single-track experiments can be used to calibrate the printability map, to produce a revised printability map. Finally, contour lines representing hatch spacing can also be added to the revised printability map to produce a final printability map that can be used to configure additive manufacturing machinery.
Core Innovation
The invention relates to a method for printing a defect-free metal part by a laser powder bed fusion system through a simulation-experiment-calibration framework. It performs a simulation of melt pool temperature and melt pool geometries for an alloy at a plurality of combinations of a laser speed parameter and a laser power parameter, and creates an initial printability map based on the simulation results.
Within the initial printability map, one or more regions correspond to one or more manufacturing defects, and the map is sampled to determine a plurality of samples. Single-track experiments are printed using the laser powder bed fusion system for the plurality of samples, and the printability map is calibrated based on the set of single-track experiments to create a revised printability map.
A plurality of hatch spacing contours are generated based on a geometric criterion that defines spacing between adjacent beads in a three-dimensional printed part. The hatch spacing contours are added to the revised printability map to create a final printability map representing a printability characteristic of the alloy at a plurality of combinations of laser speed, laser power, and hatch spacing.
A bulk sample of the alloy is printed based on the finalized printability map, a bulk sample property is measured, and an optimal combination of processing parameters is identified based on the bulk sample property. The laser powder bed fusion system is configured to print the defect-free metal part using the optimal combination of laser speed, laser power, and hatch spacing.
Claims Coverage
The document includes two independent claims: a method claim and a system claim. Across these claims, the inventive coverage is organized around four inventive features: simulation-based initial printability mapping, defect-region definition and calibration using single-track experiments, geometric hatch spacing contours, and bulk-sample-property-based selection of an optimal processing-parameter combination to print a defect-free metal part.
Simulation-based initial printability map for melt pool response
performing a simulation of melt pool temperature and melt pool geometries for an alloy at a plurality of combinations of a laser speed parameter and a laser power parameter; creating an initial printability map based on the laser speed parameter and the laser power parameter based on the simulation of melt pool temperature and melt pool geometries.
Defect-region definition and calibration using single-track experiments
defining, within the printability map, one or more regions of the printability map that correspond to one or more manufacturing defects; sampling the printability map to determine a plurality of samples within the printability map, wherein each sample comprises a value of the laser speed parameter and a value of the laser power parameter; printing a set of single-track experiments using the laser powder bed fusion system; calibrating the printability map based on the set of single-track experiments to create a revised printability map.
Geometric hatch spacing contours added to form a final printability map
generating a plurality of hatch spacing contours based on a geometric criterion, wherein the plurality of hatch spacing contours define a spacing between adjacent beads in a three-dimensional printed part; adding the plurality of hatch spacing contours to the revised printability map to create a final printability map, wherein the final printability map represents a printability characteristic of the alloy at a plurality of combinations of laser speed, laser power, and hatch spacing.
Bulk-sample property selection of an optimal processing-parameter combination for defect-free part printing
printing a bulk sample of the alloy using the laser powder bed fusion system based on the finalized printability map; measuring a bulk sample property of the bulk sample; identifying an optimal combination of processing parameters based on the bulk sample property; configuring the laser powder bed fusion system to print the defect-free metal part using the optimal combination of laser speed, laser power, and hatch spacing.
Printer-processor-memory system implementing the simulation-to-final-map pipeline
a system comprising a laser powder bed fusion printer, a processor, and a memory coupled to the processor, wherein the memory stores instructions that cause the system to perform the simulation, create the initial printability map, define defect regions, sample the map, print sample tracks, calibrate the map, generate hatch spacing contours, add the contours to create a final printability map, fabricate a bulk sample, measure a bulk sample property, identify an optimal combination of processing parameters, configure the printer, and print the defect-free metal part.
Both independent claims cover a method and system that generate a final printability map for an alloy by combining simulation of melt pool temperature and melt pool geometries, calibration using single-track experiments for samples from the map, and geometric hatch spacing contours that define spacing between adjacent beads. The claims then require printing a bulk sample, measuring a bulk sample property, identifying an optimal processing-parameter combination, and printing the defect-free metal part using that optimal combination.
Stated Advantages
Enables printing a defect-free metal part.
Documented Applications
3D part fabrication by printing a defect-free metal part using an optimal combination of laser speed, laser power, and hatch spacing based on a finalized printability map.
Measurement of bulk sample properties and identification of optimal processing parameters prior to defect-free part printing.
Interested in licensing this patent?