MELT POOL MONITORING FOR CONTROL AND DATA ANALYTICS IN LARGE-SCALE METAL ADDITIVE MANUFACTURING

Conference · Tue Oct 01 04:00:00 EDT 2019

OSTI ID:1561633

Gibson, Brian ^[1]; Bandari, Yashwanth Kumar ^[1]; Richardson, Brad ^[1]; Roschli, Alex ^[1]; Post, Brian ^[1]; Borish, Michael ^[1]; Thornton, Aaron ^[1]; Henry, William ^[1]; Lamsey, Matthew D. ^[1]; Love, Lonnie ^[1]

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1. ORNL

Laser-wire based Directed Energy Deposition (DED) processes are being developed at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility, in collaboration with GKN Aerospace, for large volume metal additive manufacturing of metallic structures. The technology has the potential to deliver reduced costs and lead times when compared to conventional methods of manufacturing in several industries. While complex structures are being produced with relatively high deposition rates and at near-net shape, issues persist with achieving consistent geometric accuracy and thermal stability. A significant research effort is focused on developing coordinated, multi-modal sensing and control for addressing these issues. An introduction to this large-volume metal process will be provided, followed by investigations into real-time thermal monitoring capabilities that support control and data analytics frameworks. Studies focused on melt pool monitoring via infrared thermography, thermal and geometric effects on melt pool size measurement, and interactions between process variables and thermal monitoring metrics are presented.

• Research Organization: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
• Sponsoring Organization: USDOE; USDOE Office of Energy Efficiency and Renewable Energy (EERE)
• DOE Contract Number: AC05-00OR22725
• OSTI ID: 1561633
• Country of Publication: United States
• Language: English