Linear Active Disturbance Rejection Control for a Laser Powder Bed Fusion Additive Manufacturing Process

Functional metal parts with complicated geometry and internal features for the aerospace and automotive industries can be created using the laser powder bed fusion additive manufacturing (AM) technique. However, the lack of uniform quality of the produced parts in terms of strength limits its enormous potential for general adoption in industries. Most of the defects in selective laser melting (SLM) parts are associated with a nonuniform melt pool size. The melt pool area may fluctuate in spite of constant SLM processing parameters, like laser power, laser speed, hatching distance, and layer thickness. This is due to heat accumulation in the current track from previously scanned tracks in the current layer. The feedback control strategy is a promising tool for maintaining the melt pool dimensions. In this study, a dynamic model of the melt pool cross-sectional area is considered. The model is based on the energy balance of lumped melt pool parameters. Energy coming from previously scanned tracks is considered a source of disturbance for the current melt pool cross-section area in the control algorithm. To track the reference melt pool area and manage the disturbances and uncertainties, a linear active disturbance rejection control (LADRC) strategy is considered. The LADRC control technique is more successful in terms of rapid reference tracking and disturbance rejection when compared to the conventional PID controller. The simulation study shows that an LADRC control strategy presents a 65% faster time response than the PID, a 97% reduction in the steady state error, and a 98% reduction in overshoot. The integral time absolute error (ITAE) performance index shows 95% improvement for reference tracking of the melt pool area in SLM. In terms of reference tracking and robustness, LADRC outperforms the PID controller and ensures that the melt pool size remains constant.