Brian A. Fisher, PhD Candidate, Carnegie Mellon University
Jack Beuth PhD, Professor, Mechanical Engineering and Director, NextManufacturing Center, Carnegie Mellon University
Powder Bed Laser Melting of Ti-6Al-4V is an important process for use in the aerospace and medical device industries. In order to ensure widespread adoption of this technology, the ability to optimize process parameters through the use of non-standard parameter sets and the ability to ensure part quality are critical. This presentation investigates the link between three process inputs: beam power, beam travel velocity, and surface temperature of the part in order to find optimal areas of processing space by mapping process inputs to process outputs of interest. Experiments were conducted at Carnegie Mellon University using an EOS M290 DMLS machine and at NIST using an internally developed laser melting test bed. Additionally, high speed imaging is used to correlate process parameters to melt pool thermal emission in order to understand how melt pools change in-situ due to parameter modifications. This understanding can guide part quality monitoring software that is based on data from more simple sensors. A resulting relationship between melt pool area, processing conditions, and melt pool thermal emission will be presented.