A Multi-view Sensor Suite/Process Model-based Control System

In Phase I Stratonics, Inc. demonstrated the feasibility of its multi-sensor/model based control system for DDM processes. In Phase II, prototype sensors and software will be developed for measuring critical parameters and controlling thermal processing. The sensors and software will be evaluated at both PSU and in the facilities of our industrial partners. The successful development of DDM thermal controls will prevent defects/flaws (porosity from cold processing) or inhomogeneous deposits (non-uniform microstructure). The innovation combines a multi-view thermal imaging sensor suite, finite element method (thermal/metallurgical) models and real-time software algorithms to control the DDM process parameters. The imaging sensors will provide thermal measurements in real-time by viewing the melt pool along the laser axis and by viewing the side of the deposit. A thermal status of the deposit is monitored and controlled by adjustment of process parameters, to guide the DDM process, so that specified and uniform microstructure is achieved. The thermal measurements will also be used as input to the FEM process model refinement, to support intelligent process design. Stratonics has formed a strong team of experts, including Penn State University and industrial partners, Optomec, Pratt & Whitney, Morris Technologies, and Boeing, leaders in additive manufacturing.