Sensing and control are key in laser-based Directed Energy Deposition (DED-LB) in terms of repeatability and good quality builds. This work presents a real-time control system where the melt-pool temperature is monitored, and the laser power is adjusted in closed-loop as control parameter. The control system includes a Field-Programmable Gate Array (FPGA) for the real-time estimation of the melt-pool temperature extracted from data from a coaxial high-speed hyperspectral camera, and a Proportional-Integral (PI) controller for the laser power regulation. The controller gains are tuned to ensure constant temperature during deposition. However, different sets of gains, with differences in the response time and transient behavior of the controller, achieve this goal but produce different deposition quality. The presented paper discusses the impact of the different controller gains on the melt-pool temperature and melt-pool size during the deposition of thin-walls and squared spirals, and compares open-loop (without control) and closed-loop (with control) cases.
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