Controls and Control Theory Commons^™

Data-Driven Porosity Prediction For Directed Energy Deposition, Georgia E. Kaufman

Electrical and Computer Engineering ETDs

Stochastic flaw formation leading to poor print quality is a major obstacle to the utility of directed energy deposition (DED), a laser and metal powder-based additive manufacturing technology for construction and repair of custom metal parts. While melt pool temperature variability is known to be a major factor in flaw formation, control schemes to decrease flaw formation are limited by a lack of physics-based models that fully and accurately describe DED. In this work, a stochastic reachability analysis with a data-driven model based on thermal images of the melt pool was conducted to determine the likelihood of violating melt pool …