Designing materials by laser powder bed fusion with machine learning-driven bi-objective optimization

Research output: Contribution to journalResearch articleContributedpeer-review

Contributors

  • Denys Y. Kononenko - , Leibniz Institute for Solid State and Materials Research Dresden (Author)
  • Dmitry Chernyavsky - , Leibniz Institute for Solid State and Materials Research Dresden (Author)
  • Wayne E. King - , The Barnes Global Advisors LLC (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, TUD Dresden University of Technology (Author)
  • Konrad Kosiba - , Leibniz Institute for Solid State and Materials Research Dresden (Author)

Abstract

To exploit the full industrial potential of additive manufacturing (AM) beyond prototyping, the resource-consuming identification of the optimal processing conditions needs to be minimized. This task becomes more challenging when multiple properties of the part shall be simultaneously optimized. We utilize machine learning (ML) methods in a case study on laser powder bed fusion (LPBF) of a Zr-based glass-forming alloy. Our experiments show that processing parameters affect density and amorphicity opposingly, demonstrating the efficacy of our ML-based approach. We employ multi-objective optimization using Gaussian Process Regression to model and predict target properties and their uncertainties of parts fabricated by LPBF – a widely used metal AM technology. With density and amorphicity as target parameters, we optimize models using the Pareto front facilitated by the Non-Dominated Sorting Genetic Algorithm II. Despite deviations in the amorphicity data, we demonstrate this method to identify the high-performance region of the process parameters and its ability to be iteratively enhanced with additional experimental data. This bi-objective optimization approach provides a robust toolset for navigating LPBF processing. It can be easily extended to a larger set of target properties and transferred to further AM technologies.

Details

Original languageEnglish
Pages (from-to)6802-6811
Number of pages10
JournalJournal of Materials Research and Technology
Volume30 (2024)
Publication statusPublished - 10 May 2024
Peer-reviewedYes

Keywords

Keywords

  • Additive manufacturing, Bulk metallic glass, Gaussian processes, Laser powder bed fusion, Machine learning