Bayesian optimization for laser powder bed fusion of defect-free AA2024

Research output: Contribution to journalResearch articleContributedpeer-review

Contributors

  • Dmitry Chernyavsky - , Leibniz Institute for Solid State and Materials Research Dresden (Author)
  • Denys Y. Kononenko - , Leibniz Institute for Solid State and Materials Research Dresden (Author)
  • Julia Kristin Hufenbach - , Leibniz Institute for Solid State and Materials Research Dresden, Freiberg University of Mining and Technology (Author)
  • Jeroen van den Brink - , Chair of Solid State Theory, Leibniz Institute for Solid State and Materials Research Dresden (Author)
  • Konrad Kosiba - , Leibniz Institute for Solid State and Materials Research Dresden (Author)

Abstract

Identifying optimal processing parameters remains a major challenge in additive manufacturing (AM), limiting its potential and broader industrial adoption. In this work, we present a Bayesian machine learning (ML) framework designed to efficiently determine optimal parameters for AM processes. We demonstrate its effectiveness through the successful processing of the AA2024 alloy into high-density components, known for its difficulty in processing, using laser powder bed fusion (PBF-LB/M). Our approach begins with Bayesian Optimization (BO) applied to an initial dataset containing only five processing parameter sets. Despite the limited data, the method accurately predicts conditions for producing crack-free components with a remarkably high density resulting in tensile properties similar to cast counterparts. We further extend the framework to perform bi-objective optimization, targeting both maximum build-up rate (BUR) and density. Experimental validation confirms that the framework can identify new parameter sets that significantly enhance BUR while maintaining high part quality. This work underscores the potential of BO strategies for accelerating optimal processing conditions discovery, especially for challenging materials and multi-objective scenarios.

Details

Original languageEnglish
Article number105022
JournalAdditive Manufacturing
Volume114
Publication statusPublished - 25 Sept 2025
Peer-reviewedYes

Keywords

Keywords

  • AA2024, Additive manufacturing, Bayesian optimization, Laser powder bed fusion, Machine learning, Mechanical properties