Openly-Controlled and Monitored, Multibeam Laser Additive Manufacturing System
Abstract
Metal Additive Manufacturing (AM) is a game changing technology with transformational potential in capability enhancement for the warfighter and battlefield logistics. To capture this potential across DoD applications, significant research is still needed to mature the technology. Commercially available laser powder bed fusion (PBF-L) equipment has limitations that create barriers for researchers to address these challenges including closed machine controls, lack of ability to tailor processing conditions, and barriers to in-process instrumentation; all in addition to limited materials choices that are holding back advancement of this strategic enabling defense manufacturing technology.This DURIP proposal is to purchase an open-source, novel multi-beam PBF-L platform equipped with in-situ monitoring capabilities. This unique instrument uses multiple beams to allow for the engineering of local thermal history during printing, enabling transformational research and developments, while building on the unique combination of fundamental knowledge and industrial experience of the proposed team of users. The research team assembled for this proposal bring together expertise in materials and process modeling, physical metallurgy, laser processing/joining, Integrated Computational Materials Science and Engineering (ICMSE), AM process control, as well as DoD applications for AM.The system will be housed at the Center for Design and Manufacturing Excellence (CDME) at The Ohio State University (OSU). CDME is the industrial manufacturing technology center at OSU and the shared facility will provide access to students and researchers from multiple universities, companies, and research laboratories across Ohio and the US.The proposed highly-integrated and open-source system with two lasers (capable for future expansion) will enable unprecedented freedom for thermal management during PBF-L in order to control preferential evaporation, thermal gradients and solidification/cooling rates, which allows the ability to locally modify composition, solidification mode and structure, crystallography, phase transformations, and strain distribution. The system will additionally beequipped with state-of-the-art video and thermal imaging to enable in-situ process and thermal history monitoring.Such cutting-edge capabilities enable the potential for local engineering of the material structure and performance while building complex parts. This driving vision will foster collaboration among the process control, materials and process modeling, metallurgy, laser processing, performance modeling and evaluation, and applications researchers within the team. The simple, open-source, and research-oriented instrument will also enable transformativedevelopments for innovative process control and real-time process and material monitoring, providing the scientific foundation for next generation machine enhancements.In support of the OSU educational mission, the team will integrate the system into AM curricula, K12 STEM outreach, and professional short courses for industrial partners and federal research laboratories. Foundationally, the system will contribute to OSUs continued long-term service to the DoD and will facilitate collaborative AM-focused partnerships with AFOSR,ONR,ARO,ARL,AFRL, NRL, NAVAIR, ARDEC and other stakeholders.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Jun 17, 2020
- Source ID
- N000142012364
Entities
People
- Michael Groeber
Organizations
- Office of Naval Research
- Ohio State University
- United States Navy