Robotic Laser Hot Wire System for Research on Additive Manufacturing via Directed Energy Deposition
Abstract
(publicly releasable)The DoD has a clear need for additively manufactured parts that are infeasible for current AM technologies beca,use of size and/or fabrication time. Moreover, the DoD needs parts with well-defined materials properties to meet performance requir,ements. Wire feed additive manufacturing (AM) is ready to be brought up to the same level as powder bed AM so that it becomes accept,ed for use in producing large-scale complex components. Powder bed (PB) & powder feed (PF) technologies are limited for multiple phy,sical reasons which include powder-introduced porosity, limited deposition rates, and limited size (PF). Although electron beam wire, feed has been available for several years, operating in a vacuum chamber with a fixed position source limits its controllability. R,obotic laser (hot-)wire feed has recently made significant progress and is ready for more extensive development via, e.g., use of a,wider set of materials than the Ti-6Al-4V being used in some current programs. Nevertheless, much remains to be learned about how th,e two heat sources (laser and hot wire) should best be used in concert and how the robotic positioning influences the deposition pro,cess. There is also a great deal to be learnt about how variations in process parameters affect material properties and also variati,on in properties within a part. Accordingly, the proposed robotic laser hot-wire deposition system offers an opportunity to place a,system in a leading research university with a unique track record of fundamental research on AM-related topics and practical implem,entation of 3D metals printing. This is a research-scale system that is a new offering in 2021 and represents an affordable approach, for university-based research. Moreover, CMU has an exceptionally strong commitment to introducing machine learning across the spec,trum from cyber security through mechanical engineering to materials science. Thus, the laser hot wire system will provide new resea,rch capability to the DoD and will contribute to education at all levels via CMUs BS minor, MS in AM, and PhD research programs, an,d will reinforce current research in the Quality Made program by providing capability that is complementary to what exists. CMU has,made a substantial investment in metals powder bed AM and there is an exceptional depth of research in robotics which means that the,re is a well-developed eco-system for the proposed system. The system will be located either on campus or in the newly built Mill-19, facility which also houses the non-profit Advanced Robotics for Manufacturing(ARM). The expected useful life of the system is at le,ast ten years.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Jul 13, 2022
- Source ID
- N000142212428
Entities
People
- Anthony Rollett
Organizations
- Carnegie Mellon University
- Office of Naval Research
- United States Navy