Periodic Reporting for period 1 - BALSAM (Boosting the surface quality and geometric accuracy in laser additive manufacturing via a novel data-driven control system design)
Reporting period: 2022-09-01 to 2024-08-31
Summary of the context and overall objectives of the project
The BALSAM project (Boosting Accuracy of Laser Additive Manufacturing) is designed to address critical challenges in the field of Laser Wire-Feed Metal Additive Manufacturing (LAM), particularly focusing on enhancing surface quality and geometric accuracy. Conducted at the University of Luxembourg (UL) with collaboration from the Fraunhofer Institute for Production Technology (F-IPT), this project aims to leverage expertise across borders to advance LAM technology.
Laser Wire-Feed Metal Additive Manufacturing is an emerging technology with immense potential in modern manufacturing, offering flexibility and customization in producing complex geometries. However, several technical challenges hinder its broader industrial adoption, including issues related to surface quality, geometric accuracy, and defects such as porosity, voids, and cracks. These defects often arise from factors like raw material contamination, process instability, and environmental disturbances, which necessitate automation and process control improvements.
The BALSAM project recognizes these challenges and seeks to provide innovative solutions through a multidisciplinary approach. By integrating advanced sensing, control systems, and data-driven methodologies, the project aims to significantly improve the quality and reliability of LAM processes. This initiative is especially relevant given the strategic importance of LAM in enhancing the competitiveness and sustainability of manufacturing industries in Europe.
The BALSAM project is structured around several key objectives aimed at overcoming the identified limitations in LAM:
1. Develop a Monitoring System: Create an advanced system for real-time data collection and fault detection during the LAM process.
2. Design a Novel Control System: Develop an innovative control system that enhances surface quality and geometric accuracy by integrating sensor-based feedback mechanisms into the LAM process.
3. Prototype Implementation: Implement the designed control system in a prototype to conduct experiments and validate its performance in real-time operations, ensuring practical applicability and effectiveness.
4. Research Management and Training: Promote knowledge transfer through education activities, including course training and dissemination of results, to build expertise and foster innovation in LAM.
The BALSAM project is strategically positioned to enhance cross-border cooperation and foster a network of excellence in LAM. By partnering with leading institutions like UL and F-IPT, the project aims to pool advanced R&D capabilities in welding, metallurgy, robotics, and simulation. This collaboration is expected to strengthen Europe’s leadership in metal additive manufacturing and create a foundation for long-term research and development.
Scientific and Technological Advancements: The project will contribute to the scientific community by addressing complex challenges in process monitoring and control systems for LAM. Results will be disseminated through publications in open-access journals and presentations at international conferences, enhancing the visibility and impact of the research.
Industrial Adoption and Economic Benefits: By improving the quality and reliability of LAM-produced parts, BALSAM is expected to increase the adoption of LAM in European industries, leading to cost efficiency and reduced raw material usage. This aligns with goals for environmental sustainability and economic competitiveness.
On the other hand, the integration of social sciences and humanities plays a crucial role in understanding the broader implications of LAM technology adoption. The BALSAM project considers factors such as workforce adaptation, ethical considerations in automation, and the socioeconomic impacts of technological advancements. By addressing these aspects, the project aims to ensure that technological progress aligns with societal needs and values.
To maximize the impact of its findings, the BALSAM project will engage stakeholders from academia, industry, and government through various channels:
• Workshops and Special Events: Engage with industry stakeholders and production clusters through workshops and events, such as DIH ON TOUR, to promote knowledge exchange and collaboration.
• National and International Symposia: Participate in symposia on LAM and robotics, like the Lasers in Manufacturing – LIM conference, to share insights and foster dialogue among researchers and practitioners.
• Publications and Conferences: Publish research findings in prestigious journals and present at international conferences, ensuring wide dissemination and integration of results into ongoing research efforts.
Finally, the BALSAM project aims to make significant strides in improving the accuracy and reliability of Laser Wire-Feed Metal Additive Manufacturing. By addressing key technical challenges and fostering cross-disciplinary collaboration, the project is poised to enhance the competitiveness of European industries and contribute to sustainable manufacturing practices. Through its strategic focus and comprehensive dissemination efforts, BALSAM will pave the way for future research and innovation in the field of additive manufacturing.
Laser Wire-Feed Metal Additive Manufacturing is an emerging technology with immense potential in modern manufacturing, offering flexibility and customization in producing complex geometries. However, several technical challenges hinder its broader industrial adoption, including issues related to surface quality, geometric accuracy, and defects such as porosity, voids, and cracks. These defects often arise from factors like raw material contamination, process instability, and environmental disturbances, which necessitate automation and process control improvements.
The BALSAM project recognizes these challenges and seeks to provide innovative solutions through a multidisciplinary approach. By integrating advanced sensing, control systems, and data-driven methodologies, the project aims to significantly improve the quality and reliability of LAM processes. This initiative is especially relevant given the strategic importance of LAM in enhancing the competitiveness and sustainability of manufacturing industries in Europe.
The BALSAM project is structured around several key objectives aimed at overcoming the identified limitations in LAM:
1. Develop a Monitoring System: Create an advanced system for real-time data collection and fault detection during the LAM process.
2. Design a Novel Control System: Develop an innovative control system that enhances surface quality and geometric accuracy by integrating sensor-based feedback mechanisms into the LAM process.
3. Prototype Implementation: Implement the designed control system in a prototype to conduct experiments and validate its performance in real-time operations, ensuring practical applicability and effectiveness.
4. Research Management and Training: Promote knowledge transfer through education activities, including course training and dissemination of results, to build expertise and foster innovation in LAM.
The BALSAM project is strategically positioned to enhance cross-border cooperation and foster a network of excellence in LAM. By partnering with leading institutions like UL and F-IPT, the project aims to pool advanced R&D capabilities in welding, metallurgy, robotics, and simulation. This collaboration is expected to strengthen Europe’s leadership in metal additive manufacturing and create a foundation for long-term research and development.
Scientific and Technological Advancements: The project will contribute to the scientific community by addressing complex challenges in process monitoring and control systems for LAM. Results will be disseminated through publications in open-access journals and presentations at international conferences, enhancing the visibility and impact of the research.
Industrial Adoption and Economic Benefits: By improving the quality and reliability of LAM-produced parts, BALSAM is expected to increase the adoption of LAM in European industries, leading to cost efficiency and reduced raw material usage. This aligns with goals for environmental sustainability and economic competitiveness.
On the other hand, the integration of social sciences and humanities plays a crucial role in understanding the broader implications of LAM technology adoption. The BALSAM project considers factors such as workforce adaptation, ethical considerations in automation, and the socioeconomic impacts of technological advancements. By addressing these aspects, the project aims to ensure that technological progress aligns with societal needs and values.
To maximize the impact of its findings, the BALSAM project will engage stakeholders from academia, industry, and government through various channels:
• Workshops and Special Events: Engage with industry stakeholders and production clusters through workshops and events, such as DIH ON TOUR, to promote knowledge exchange and collaboration.
• National and International Symposia: Participate in symposia on LAM and robotics, like the Lasers in Manufacturing – LIM conference, to share insights and foster dialogue among researchers and practitioners.
• Publications and Conferences: Publish research findings in prestigious journals and present at international conferences, ensuring wide dissemination and integration of results into ongoing research efforts.
Finally, the BALSAM project aims to make significant strides in improving the accuracy and reliability of Laser Wire-Feed Metal Additive Manufacturing. By addressing key technical challenges and fostering cross-disciplinary collaboration, the project is poised to enhance the competitiveness of European industries and contribute to sustainable manufacturing practices. Through its strategic focus and comprehensive dissemination efforts, BALSAM will pave the way for future research and innovation in the field of additive manufacturing.
Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far
The BALSAM project has made significant progress in advancing the understanding and application of Laser Wire-Feed Metal Additive Manufacturing (LWAM) through a series of technical and scientific activities. The project has focused on three main areas: literature review, control theory development, and process study.
Literature Review
The project team conducted a comprehensive literature review to establish a solid foundation for understanding LWAM technology. This review was published in an open-access journal and serves as a critical resource for the field. Key highlights of the literature review include:
• Overview of LWAM Technology: The review paper provides an in-depth examination of LWAM, which uses a laser to heat and melt a metallic alloy wire, depositing it layer by layer to create three-dimensional metal parts. The advantages of LWAM include high speed, cost-effectiveness, precision control, and the capability to produce complex geometries with improved metallurgical properties.
• Identification of Key Aspects: The review emphasizes critical areas such as parametric modeling, monitoring systems, control algorithms, and path-planning approaches. These areas are essential for advancing the industrial application of LWAM.
• Research Opportunities: The study identifies gaps in the existing literature and suggests potential research directions, aiming to bridge these gaps and support the integration of LWAM into industrial processes.
Reference: Abuabiah, M., Mbodj, N.G. Shaqour, B., Herzallah, L., Juaidi, A., Abdallah, R., and Plapper, P. (2023). Advancements in Laser Wire-Feed Metal Additive Manufacturing: A Brief Review. Materials, 16(5), p.2030.
Control Theory
An achievement of the BALSAM project is the development and publication of a novel non-iterative direct data-driven control technique. This technique will be used later for enhancing LWAM processes and involves the following key aspects:
• LTI Controller Design: The technique deals with designing linear time-invariant (LTI) controllers by directly identifying the controller from input-output data, bypassing the need for traditional plant identification methods.
• Set-Membership Errors-in-Variables Problem: The control design problem is formulated as a set-membership errors-in-variables problem, allowing for the determination of feasible controller parameters that match a given reference model's behavior.
• Simulation and Experimental Validation: The effectiveness of this technique has been validated through simulations and experimental results.
Reference: Abuabiah, M., Cerone, V., Pirrera, S., and Regruto, D. (2023). A Non-Iterative Approach to Direct Data-Driven Control Design of MIMO LTI Systems. IEEE Access, 11, pp.121671-121687.
Process Study
The project also focused on a detailed study of process parameters and their impact on bead geometry in LWAM. This study, presented at a conference and in an ongoing open-access journal publication, involved the following activities:
• Parameter Study: The study investigated the effects of varying laser power, wire feed rate, traverse speed, and welding angle on the geometry of deposited beads in LWAM.
• Experimental Design: A factorial design experiment using the Box-Behnken method was conducted to analyze the interactions between these parameters and their influence on bead height and width.
• Findings: The study provided valuable insights into the complex relationships between process parameters, contributing to improved geometric accuracy and process stability. This understanding is vital for automation and series production of LWAM components.
Reference: Weidemann, T., Abuabiah, M., Shaqour, B., Day, R., Bergs, T., and Plapper, P. (2023). Influence on the Bead Geometry in Laser Metal Deposition with Wire.
Outcomes and Future Directions
The technical and scientific activities conducted under the BALSAM project have led to several key outcomes:
• Enhanced Knowledge Base: The comprehensive literature review has enriched the understanding of LWAM, providing a foundation for future research and development efforts.
• Innovative Control Solutions: The development of a novel control technique offers a promising approach to improving process control and reliability in LWAM.
• Process Optimization Insights: The process study has generated valuable data on parameter interactions, informing strategies to enhance geometric accuracy and stability in LWAM.
These achievements position the BALSAM project as a contributor to the advancement of LWAM technology, paving the way for its broader industrial application and integration. Future research will continue to build on these findings, exploring new control strategies, process optimizations, and industrial implementations.
Literature Review
The project team conducted a comprehensive literature review to establish a solid foundation for understanding LWAM technology. This review was published in an open-access journal and serves as a critical resource for the field. Key highlights of the literature review include:
• Overview of LWAM Technology: The review paper provides an in-depth examination of LWAM, which uses a laser to heat and melt a metallic alloy wire, depositing it layer by layer to create three-dimensional metal parts. The advantages of LWAM include high speed, cost-effectiveness, precision control, and the capability to produce complex geometries with improved metallurgical properties.
• Identification of Key Aspects: The review emphasizes critical areas such as parametric modeling, monitoring systems, control algorithms, and path-planning approaches. These areas are essential for advancing the industrial application of LWAM.
• Research Opportunities: The study identifies gaps in the existing literature and suggests potential research directions, aiming to bridge these gaps and support the integration of LWAM into industrial processes.
Reference: Abuabiah, M., Mbodj, N.G. Shaqour, B., Herzallah, L., Juaidi, A., Abdallah, R., and Plapper, P. (2023). Advancements in Laser Wire-Feed Metal Additive Manufacturing: A Brief Review. Materials, 16(5), p.2030.
Control Theory
An achievement of the BALSAM project is the development and publication of a novel non-iterative direct data-driven control technique. This technique will be used later for enhancing LWAM processes and involves the following key aspects:
• LTI Controller Design: The technique deals with designing linear time-invariant (LTI) controllers by directly identifying the controller from input-output data, bypassing the need for traditional plant identification methods.
• Set-Membership Errors-in-Variables Problem: The control design problem is formulated as a set-membership errors-in-variables problem, allowing for the determination of feasible controller parameters that match a given reference model's behavior.
• Simulation and Experimental Validation: The effectiveness of this technique has been validated through simulations and experimental results.
Reference: Abuabiah, M., Cerone, V., Pirrera, S., and Regruto, D. (2023). A Non-Iterative Approach to Direct Data-Driven Control Design of MIMO LTI Systems. IEEE Access, 11, pp.121671-121687.
Process Study
The project also focused on a detailed study of process parameters and their impact on bead geometry in LWAM. This study, presented at a conference and in an ongoing open-access journal publication, involved the following activities:
• Parameter Study: The study investigated the effects of varying laser power, wire feed rate, traverse speed, and welding angle on the geometry of deposited beads in LWAM.
• Experimental Design: A factorial design experiment using the Box-Behnken method was conducted to analyze the interactions between these parameters and their influence on bead height and width.
• Findings: The study provided valuable insights into the complex relationships between process parameters, contributing to improved geometric accuracy and process stability. This understanding is vital for automation and series production of LWAM components.
Reference: Weidemann, T., Abuabiah, M., Shaqour, B., Day, R., Bergs, T., and Plapper, P. (2023). Influence on the Bead Geometry in Laser Metal Deposition with Wire.
Outcomes and Future Directions
The technical and scientific activities conducted under the BALSAM project have led to several key outcomes:
• Enhanced Knowledge Base: The comprehensive literature review has enriched the understanding of LWAM, providing a foundation for future research and development efforts.
• Innovative Control Solutions: The development of a novel control technique offers a promising approach to improving process control and reliability in LWAM.
• Process Optimization Insights: The process study has generated valuable data on parameter interactions, informing strategies to enhance geometric accuracy and stability in LWAM.
These achievements position the BALSAM project as a contributor to the advancement of LWAM technology, paving the way for its broader industrial application and integration. Future research will continue to build on these findings, exploring new control strategies, process optimizations, and industrial implementations.
Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)
The BALSAM project has achieved significant advancements in the field of manufacturing technology, particularly with its innovations in laser wire-feed additive manufacturing (LWAM) and advanced control systems. These results have had a economic and industrial impact by improving manufacturing efficiency, reducing material waste, and cutting operational costs through enhanced monitoring and control systems.
Beyond its immediate outcomes, the project has led to the acceptance of the METALINK initiative under Horizon Europe Target-X, which will build on BALSAM's successes by integrating 5G technology to further enhance precision and efficiency in additive manufacturing processes.
Overview of Results
BALSAM’s contributions to laser wire-feed additive manufacturing have been disseminated through a range of scientific publications and presentations. Below is a summary of the project’s dissemination efforts:
Scientific Publications:
Abuabiah, M. et al., 2023, Advancements in laser wire-feed metal Additive Manufacturing: A brief review. Materials, 16(5), p.2030.
Abuabiah, M. et al., 2023, A non-iterative approach to direct data-driven control design of MIMO LTI systems. IEEE Access, 11, pp.121671-121687.
Weidemann, T. et al., 2024, Influence on the bead geometry in Laser Metal Deposition with wire. In Lasers in Manufacturing Conference 2023.
Abuabiah, M. et al., Investigating the Impact of Process Parameters on Bead Geometry in Laser Wire-Feed Metal Additive Manufacturing. Under Review.
Conference Presentations:
2024: 22nd International Conference on Research and Education in Mechatronics, Jordan.
2023: Lasers in Manufacturing Conference, Munich, Germany.
2022: 10th International Conference on Control, Mechatronics and Automation, University of Luxembourg.
Public Outreach:
2024: Annual IAESTE Conference, Cartagena, Colombia.
2023: Robotics Technology Workshop, An-Najah National University.
2023: Smart Manufacturing Meeting, Chambre de Commerce, Luxembourg.
2022: EuroScience Open Forum (ESOF), Leiden, Netherlands.
2022: Robotix-Academy Summer School, University of Lorraine, Metz, France.
2022: Luxembourg Digital Innovation Hub Workshop, University of Luxembourg.
Beyond its immediate outcomes, the project has led to the acceptance of the METALINK initiative under Horizon Europe Target-X, which will build on BALSAM's successes by integrating 5G technology to further enhance precision and efficiency in additive manufacturing processes.
Overview of Results
BALSAM’s contributions to laser wire-feed additive manufacturing have been disseminated through a range of scientific publications and presentations. Below is a summary of the project’s dissemination efforts:
Scientific Publications:
Abuabiah, M. et al., 2023, Advancements in laser wire-feed metal Additive Manufacturing: A brief review. Materials, 16(5), p.2030.
Abuabiah, M. et al., 2023, A non-iterative approach to direct data-driven control design of MIMO LTI systems. IEEE Access, 11, pp.121671-121687.
Weidemann, T. et al., 2024, Influence on the bead geometry in Laser Metal Deposition with wire. In Lasers in Manufacturing Conference 2023.
Abuabiah, M. et al., Investigating the Impact of Process Parameters on Bead Geometry in Laser Wire-Feed Metal Additive Manufacturing. Under Review.
Conference Presentations:
2024: 22nd International Conference on Research and Education in Mechatronics, Jordan.
2023: Lasers in Manufacturing Conference, Munich, Germany.
2022: 10th International Conference on Control, Mechatronics and Automation, University of Luxembourg.
Public Outreach:
2024: Annual IAESTE Conference, Cartagena, Colombia.
2023: Robotics Technology Workshop, An-Najah National University.
2023: Smart Manufacturing Meeting, Chambre de Commerce, Luxembourg.
2022: EuroScience Open Forum (ESOF), Leiden, Netherlands.
2022: Robotix-Academy Summer School, University of Lorraine, Metz, France.
2022: Luxembourg Digital Innovation Hub Workshop, University of Luxembourg.