Hybrid Modeling Approach for Melt Pool Prediction in Laser Powder Bed Fusion Additive Manufacturing

Published

August 16, 2020

Author(s)

Tesfaye M. Moges, Zhuo Yang, Kevontrez K. Jones, Shaw C. Feng, Paul W. Witherell, Yan Lu

Abstract

Multi-scale multi-physics computational models are a promising tool to provide detailed insights to understand the process-structure-property-performance relationships in additive manufacturing (AM) processes. To take advantage of the strengths of both physics-based and data-driven models, we propose a novel hybrid modeling framework for laser powder bed fusion (L-PBF) processes. Our unbiased model integration method combines physics-based data and measurement data for approaching more accurate prediction of melt pool width. Both a high-fidelity computational fluid dynamics (CFD) model and experiments utilizing optical images are used to generate a combined dataset of melt pool widths. From this aggregated dataset, a hybrid model is developed using data-driven modeling techniques, including polynomial regression and Kriging methods. The performance of the hybrid model is evaluated by computing the average relative error and compared with the results of the simulations and surrogate models constructed from the original CFD model and experimental measurements. It is found that the proposed hybrid model performs better in terms of prediction accuracy and computational time. Future work includes a conceptual introduction on the use of an AM ontology to support improved model and data selection when constructing hybrid models. This study can be viewed as a significant step towards the use of hybrid models as predictive models with improves accuracy without the sacrifice of speed.

Proceedings Title

Proceedings of the ASME 2020 International Design Engineering Technical Conferences and Computers and
Information in Engineering Conference (IDETC/CIE 2020)

Conference Dates

August 16-19, 2020

Conference Location

St. Louis, MO

Pub Type

Conferences

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Keywords

Additive manufacturing, Laser powder bed fusion, Hybrid model, Melt pool width, Gaussian process/Kriging, Data-driven surrogate model, Ontology

Citation

Moges, T. , Yang, Z. , Jones, K. , Feng, S. , Witherell, P. and Lu, Y. (2020), Hybrid Modeling Approach for Melt Pool Prediction in Laser Powder Bed Fusion Additive Manufacturing, Proceedings of the ASME 2020 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference (IDETC/CIE 2020), St. Louis, MO, [online], https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=929913 (Accessed October 9, 2025)