Transforming Additive Manufacturing via In-situ and Operando Synchrotron Imaging
Abstract
The offeror proposes to develop and demonstrate in-situ diagnostics capable of determining generation of defects as a function of process parameters as material is being incorporated into a bulk sample during a blown powder laser additive manufacturing (AM) process. The proposed approach is to integrate both ultra-fast synchrotron imaging and IR thermography into the AM processing instrumentation. Coupled with a novel digital image correlation (DIC) module which will be designed and implemented for these diagnostics (in collaboration with Oregon State Univ ~ funded separately by ONR 332), the x-ray and thermographic data will be converted into 3D mapping of the induced strains as well as the defects (types, sizes, quantity) as a function of process parameters in real time. In addition, this project will focus on using the radiographic and optical DIC to track the contraction of functionally graded coatings produced via AM in situ..New algorithms will be developed to enable cross-correlation of the combined in-situ synchrotron X-ray radiography and the IR thermography date to reveal sub-surface ~invisible~ defects from the surface. The cross-correlation of in-situ synchrotron X-ray radiography with IR thermography using DIC will provide a measure of the effects of process conditions on the material microstructure which in turn will be used to develop real time control algorithms to ensure reproducibility. In addition, a study properties, (residual stress, defects, phase transformations, microstructural feature formation) as a function of process conditions (material characteristics, powder flow, laser power, raster rate, and melting, mixing in the weld pool, solidification rate) will be undertaken to determine (using advanced AI methods) optimized multivariate process conditions to achieve desired material/component mechanical properties for the intended application.This is a highly ambitious, multidisciplinary proposal that addresses technical challenges that are critical to the success of the Navy~s AM program, and especially to the prospects of inserting this technology into service for the Navy and USMC. One of the most critical challenges to the wide adoption of additive manufacturing is the large variability in quality of parts made using this relatively new technology. The proposed effort goes to the heart of what is needed to address this challenge, establish the means to quickly establish process conditions that will assure reliable, reproducible results, and accelerate acceptance, and establish qualification and certification methods/standards for this revolutionary technology.The PI has laid out a well structured approach that demonstrates his depth of understanding of the technical and implementation challenges involved. It directly supports the Operational Endurance priority in the Naval R&D Framework. Furthermore, this project will prepare the ground for a much broader ability to design, prototype new materials/components and repair existing structures/component much more rapidly than is currently possible ~ especially when forward deployed.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Aug 20, 2019
- Source ID
- N629091912109
Entities
People
- Peter P Lee
Organizations
- Office of Naval Research
- United States Navy
- University College London