Control and monitoring of in-situ L-PBF process characteristics

• Grant number: 25/05295-6
• Support Opportunities: Scholarships in Brazil - Doctorate
• Start date: June 01, 2025
• End date: May 31, 2029
• Field of knowledge: Engineering - Materials and Metallurgical Engineering
• Principal Investigator: Alfredo Rocha de Faria
• Grantee: Yuri de Paula Roberto de Campos
• Host Institution: Divisão de Engenharia Mecânica (IEM). Instituto Tecnológico de Aeronáutica (ITA). Ministério da Defesa (Brasil). São José dos Campos , SP, Brazil
• Company: Ministério da Defesa (Brasil). Instituto Tecnológico de Aeronáutica (ITA). Divisão de Engenharia Mecânica (IEM)
• Associated research grant: 21/11258-5 - Engineering Research Center for the Aerial Mobility of the Future (ERC-AMF), AP.PCPE

Abstract

The doctoral research project entitled "Control and monitoring of in-situ L-PBF process characteristics" aims to develop and implement a quality control system for the laser powder bed fusion (L-PBF) process. This process, fundamental to additive manufacturing, is influenced by over 50 parameters, which can be categorized into input parameters and boundary condition parameters. Input parameters are controllable by the operator and include aspects such as atmospheric conditions, powder deposition, and sweeping, while boundary condition parameters are related to the material characteristics, the geometry being processed, and the machine parameters. The main objective of the project is to enhance the control of L-PBF process characteristics during different processing stages to ensure the production of high-quality parts. This goal will be achieved through effective monitoring and control of the process temperature, powder deposition, and the melt pool itself. Given the critical nature of the parts produced, especially in the aerospace industry, it is imperative that the process meets stringent quality and safety standards, which requires a systematic approach to process qualification. To achieve this goal, the project outlines several key activities: 1- Literature review and analysis of commercial solutions to identify existing control methods, analyzing the effectiveness of each at different stages of the manufacturing process. 2- Evaluation of the main phenomena that occur during the L-PBF process and that may adversely affect the final quality of the parts. 3- Proposal of an innovative process monitoring method that is suitable for application in the aerospace industry, taking into account the standards and certifications required by the sector. The methodology adopted for the research includes a comprehensive review of the existing literature in the fields of metallic additive manufacturing, with a specific focus on the L-PBF process, and the control methods necessary to ensure the integrity of the parts. In addition, aerospace standards and certifications will be reviewed to ensure that the proposed additive manufacturing process meets all regulatory and quality requirements. This review will also assist in identifying the most critical requirements that demand strict quality control. The project's results are expected to significantly contribute to the advancement of additive manufacturing, particularly in terms of improving the reliability and quality of the parts produced, reducing quality variations, and increasing the repeatability of additive manufacturing processes. (AU)