Abstract: An additive manufacturing (AM) method is provided. The method includes performing a laser powder bed fusion (L-PBF) process on the powder layer. Then, a first surface roughness value of the powder layer after the L-PBF process is obtained to generate a first surface profile. An absorptivity and a set of re-melting process parameters data are used to perform a heat transfer simulation. A second surface profile of the powder layer after laser re-melting is obtained by using the first surface profile and a low-pass filter. Then, the set of re-melting process parameters data is adjusted iteratively to perform the heat transfer simulation until a second surface roughness value predicted from the second surface profile is smaller than or equal to a surface roughness threshold, thereby obtaining optimal values of re-melting process parameters for performing a re-melting process to reduce a surface roughness of a powder layer after the L-PBF process.

Abstract: An additive manufacturing (AM) method is provided. The method includes performing a laser powder bed fusion (L-PBF) process on the powder layer. Then, a first surface roughness value of the powder layer after the L-PBF process is obtained to generate a first surface profile. An absorptivity and a set of re-melting process parameters data are used to perform a heat transfer simulation. A second surface profile of the powder layer after laser re-melting is obtained by using the first surface profile and a low-pass filter. Then, the set of re-melting process parameters data is adjusted iteratively to perform the heat transfer simulation until a second surface roughness value predicted from the second surface profile is smaller than or equal to a surface roughness threshold, thereby obtaining optimal values of re-melting process parameters for performing a re-melting process to reduce a surface roughness of a powder layer after the L-PBF process.

Abstract: A method of performing powder bed fusion process is provided. A powder bed and a group of information of the powder bed are obtained. A powder bed simulation is performed to obtain a thickness of the powder bed and a packing density. Then, a group of parameters of a laser is obtained. A Ray Tracing simulation for the powder layer and a heat transfer simulation are performed. A first surrogate model is constructed to obtain first processing maps. The points in the first processing maps with the depths of the melt pool that are greater than a predetermined depth value and smaller than a laser beam radius are a first group of parameter values. A parameter setting operation is performed by using the first group of parameter values. A laser melting operation is performed, and a temperature distribution is measured by using an infrared thermal camera.

Abstract: A method of performing powder bed fusion process is provided. A powder bed and a group of information of the powder bed are obtained. A powder bed simulation is performed to obtain a thickness of the powder bed and a packing density. Then, a group of parameters of a laser is obtained. A Ray Tracing simulation for the powder layer and a heat transfer simulation are performed. A first surrogate model is constructed to obtain first processing maps. The points in the first processing maps with the depths of the melt pool that are greater than a predetermined depth value and smaller than a laser beam radius are a first group of parameter values. A parameter setting operation is performed by using the first group of parameter values. A laser melting operation is performed, and a temperature distribution is measured by using an infrared thermal camera.