In-Process Monitoring of Part Quality in Laser Powder Bed Fusion Additive Manufacturing Process Using Acoustic Emission Sensors
Year: 2025
Type: article
DOI: 10.1115/1.4067848
Institutions: Virginia Tech, University of Oklahoma
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: closed
Awards: G1379225946, Biosensor Data Fusion for Real-Time Monitoring of Global Neurophysiological Function, PURPOSE: THE PURPOSE OF THIS GRANT IS TO ENABLE RESEARCH INTO FLAW-FREE AND CYBERSECURE PRODUCTION OF METAL PARTS MADE USING ADDITIVE MANUFACTURING PROCESSES THROUGH DEVELOPMENT AND APPLICATION OF NOVEL COMPUTATIONAL TOOLS FOR REAL-TIME PROCESS MONITORING AND AUTONOMOUS FLAW CORRECTION BASED ON THE CONCEPT OF EDGE COMPUTING.ACTIVITIES TO BE PERFORMED: FAST AND ACCURATE PREDICTION OF THERMAL HISTORY BY REPRESENTING THE PART GEOMETRY IN TERMS OF RANDOMLY SAMPLED NODES, CONSTRUCTING A NETWORK GRAPH BY CONNECTING NODES, AND SIMULATING MELTING OF EACH LAYER TO PREDICT TEMPERATURE DISTRIBUTIONS. DETECT DRIFTS USING REAL-TIME SENSOR DATA AND SIMULATIONS BY MONITORING THE LAYER TEMPERATURE USING VARIOUS SENSORS, INCORPORATING INSTANTANEOUS MELT POOL TEMPERATURE INTO THE GRAPH THEORY MODEL, AND DETECTING ONSET OF FLAW FORMATION AS THE PART IS BEING BUILT. CORRECT POTENTIAL FLAWS BY QUANTIFYING THE SEVERITY OF THE PROCESS DRIFT, IDENTIFYING A SAFE PROCESS CORRECTION STRATEGY, AND CHANGE PROCESS PARAMETERS TO CORRECT THE DRIFT. EXPECTED OUTCOMES: SOFTWARE AND HARDWARE TOOLS THAT ALLOW A PREDICTION-DETECTION-CORRECTION CONTROL LOOP THAT DOES NOT REQUIRE TRANSFERRING DATA BACK AND FORTH FROM THE ADDITIVE MANUFACTURING MACHINE, THUS ENABLING THE SECURE CREATION OF METAL ADDITIVE MANUFACTURING PARTS WITHOUT DEFECTS.INTENDED BENEFICIARIES: MANUFACTURERS OF THIRD-PARTY MEASUREMENT TOOLS VENDOR FOR LASER POWDER BED FUSION AND ADDITIVE MANUFACTURING MACHINES WILL BENEFIT FROM THE NEW TOOLS TO INTEGRATE INTO NEW AND EXISTING ADDITIVE MANUFACTURING MACHINES. FUNDS FROM THIS GRANT WILL BE USED TO EMPLOY GRADUATE STUDENTS, WHO WILL BENEFIT BY GAINING EDUCATION AND EXPERIENCE IN ADDITIVE MANUFACTURING, A GROWING ADVANCED MANUFACTURING PROCESS.SUBRECIPIENT ACTIVITIES: VT INTENDS TO SUBCONTRACT WITH DREXEL UNIVERSITY AND NAVAJO TECHNICAL UNIVERSITY (NTU). THESE COLLABORATORS WILL BE FOCUSED ON SEPARATE ASPECTS OF THE PROJECT. DREXEL WILL BE PRIMARILY INVOLVED IN MATERIALS CHARACTERIZATION WHILE NTU?S EFFORT WILL BE AIM AT THE METROLOGY OF THE RESEARCH.
OpenAlex ID: W4407194897