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Journal of Intelligent Manufacturing

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30-09-2021

Data-driven models for predictions of geometric characteristics of bead fabricated by selective laser melting

Authors: Thai Le-Hong, Pai Chen Lin, Jian-Zhong Chen, Thinh Duc Quy Pham, Xuan Van Tran

Published in: Journal of Intelligent Manufacturing | Issue 3/2023

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Abstract

In this paper, the effects of two key process parameters of the selective laser melting process, namely laser power and scanning speed, on the single-track morphologies and the bead characteristics, especially the depth-to-width D/W and height-to-width H/W ratios, were investigated using both experimental and Machine Learning (ML) approaches. A total of 840 single tracks were fabricated with several combinations of laser power and scanning speed levels. Surface morphologies of the single tracks and bead profiles were thoroughly investigated, providing a track-type map and the evolutions of the bead characteristics as a function of laser power and scanning speed. The results indicate neither severe balling nor keyholing effect for all combinations of laser power and scanning speed. Besides, simple relationships cannot accurately describe the evolutions of the D/W and H/W ratios as a function of laser power and scanning speed. Two Machine Learning-based regression models, Random Forest and Artificial Neural Network, were chosen to estimate the D/W and H/W ratios using laser power and scanning speed. The Bayesian optimization algorithm was employed to optimize the model hyperparameter selection. Both Machine Learning-based models appear to be able to predict reasonably well the two aspect ratios, D/W and H/W, with an overall R² value reaching about 90%, evaluated on the cross-validation dataset after a few seconds of training time, respectively.

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Title: Data-driven models for predictions of geometric characteristics of bead fabricated by selective laser melting
Authors: Thai Le-Hong
Pai Chen Lin
Jian-Zhong Chen
Thinh Duc Quy Pham
Xuan Van Tran
Publication date: 30-09-2021
Publisher: Springer US
Published in: Journal of Intelligent Manufacturing / Issue 3/2023
Print ISSN: 0956-5515
Electronic ISSN: 1572-8145
DOI: https://doi.org/10.1007/s10845-021-01845-5

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