TY - GEN A1 - Ertugrul, Gökhan A1 - Hälsig, Andre A1 - Rimpl, Robert A1 - Hensel, Jonas A1 - Härtel, Sebastian T1 - Artificial neural network based calibration of Goldak heat source parameters in tandem plasma transferred arc process using finite element analysis T2 - The international journal of advanced manufacturing technology N2 - The paper proposes a novel approach for determining multiple heat source parameters to achieve the necessary accuracy in the numerical prediction for a parallel tandem plasma transferred arc process. An artificial neural network (ANN) approach as a supervised learning–based artificial intelligence (AI) was used to model the complex relationship between heat distribution and tandem/dual heat source parameters based on finite element analysis (FEA). This study presents the first ANN-assisted numerical simulation for multiple heat source optimization of the tandem plasma transferred arc process. The model demonstrated high accuracy in predicting and calibrating the tandem heat source parameters, based on systematic simulation trials of the tandem plasma transferred arc welding. The results of the tandem heat source determined by ANN-assisted FEA were verified using experimental data on melt pool size and substrate distortion. This verification considered metrics such as penetration width, penetration depth, melt pool length, melt pool half-width, and the absolute distortion (measured as the difference between minimum and maximum displacement), with relative errors of 7.0%, 7.6%, 0.4%, 1.9%, and 9.7%, respectively. Y1 - 2025 U6 - https://doi.org/10.1007/s00170-025-15843-x SN - 0268-3768 VL - 139 SP - 2349 EP - 2363 PB - Springer Nature CY - London ER - TY - GEN A1 - Emdadi, Aliakbar A1 - Yang, Yitong A1 - Szyndler, Joanna A1 - Jensch, Felix A1 - Ertugrul, Gökhan A1 - Tovar, Michael A1 - Härtel, Sebastian A1 - Weiß, Sabine T1 - Highly printable Fe₃Al intermetallic alloy T2 - Metals : open access journal N2 - Intermetallic Fe₃Al-based alloys reinforced with Laves-phase precipitates are emerging as potential replacements for conventional high-alloy steels and possibly polycrystalline Ni-based superalloys in structural applications up to 700 °C. Their impressive mechanical properties, however, are offset by limited fabricability and poor machinability due to their severe brittleness. High tool wear during finish-machining, which is still required for components such as turbine blades, remains a key barrier to their broader adoption. In contrast to conventional manufacturing routes, additive manufacturing offers a viable solution by enabling near-net-shape manufacturing of difficult-to-machine iron aluminides. In the present study, laser powder bed fusion was used to produce an Fe-25Al-1.5Ta intermetallic containing strengthening Laves-phase precipitates, and the porosity, microstructure and phase composition were characterized as a function of the process parameters. The results showed that preheating the build plate to 650 °C effectively suppressed delamination and macrocrack formation, even though noticeable cracking still occurred at the high scan speed of 1000 mm/s. X-ray tomography revealed that samples fabricated with a lower scan speed (500 mm/s) and a higher layer thickness (0.1 mm) contained larger, irregularly shaped pores, whereas specimens printed at the same volumetric energy density (40 J/mm3) but with different parameter sets exhibited smaller fractions of predominantly spherical pores. All samples contained mostly elongated grains that were either oriented close to <001> relative to the build direction or largely texture-free. X-ray diffraction confirmed the presence of Fe₃Al and C14-type (Fe, Al)₂Ta Laves phase in all samples. Hardness values fell within a narrow range (378–398 HV10), with only a slight reduction in the specimen exhibiting higher porosity. KW - Fe₃Al intermetallic KW - Iron aluminide KW - Additive manufacturing KW - Laser powder bed fusion (LPBF) KW - Porosity KW - Microstructure Y1 - 2026 U6 - https://doi.org/10.3390/met16010005 VL - 16 IS - 5 SP - 1 EP - 15 PB - MDPI CY - Basel ER - TY - GEN A1 - Jensch, Felix A1 - Sviridov, Alexander A1 - Dubinin, Sergej A1 - Karabulut, Fatih A1 - Weiß, Sabine A1 - Härtel, Sebastian T1 - Parameter optimization for low-porosity Ti-6Al-4V parts produced using accelerated PBF-LB process T2 - Progress in additive manufacturing N2 - In this study, the influence of various process parameters on the porosity of Ti-6Al-4V parts fabricated via Powder Bed Fusion – Laser Based (PBF-LB) is investigated. Three different layer thicknesses (30 μm, 60 μm, and 120 μm) were analyzed to define process windows enabling a build-rate acceleration while keeping the porosity below 0.1%. Through iterative parameter refinement, the effects of laser power, scan speed and hatch distance were examined in terms of linear energy density (LED), energy transmission density (ETD) and volumetric energy density (VED), and their influence on the formation of process-related defects such as pores. Correlations between these energy metrics and pore formation types (keyhole vs. lack-of-fusion) are discussed. The results demonstrate that process acceleration by a factor of more than 3 is possible while maintaining high quality of the components in terms of internal porosity. In addition, an accelerated method for manufacturing components using the PBF-LB process is presented, in which components are manufactured at very high build-rates but with increased porosity and then brought to the target porosity of 0.1% using the HIP process. This has made it possible to accelerate the build-rate in PBF-LB production by a further 32%. Accounting for the additional time required for HIP, the HIP route is faster than using the accelerated, which achieves the target porosity in as-built condition, for parts larger than 1421 cm3. KW - Laser powder bed fusion KW - Process parameter optimization KW - Porosity analysis KW - Ti-6Al-4V KW - Additive manufacturing productivity Y1 - 2026 U6 - https://doi.org/10.1007/s40964-025-01510-w SN - 2363-9520 SP - 1 EP - 17 PB - Springer CY - Cham ER -