Development of In-Process Monitoring Closed-Loop Feedback for Use in Aluminum Alloy Additive Manufacturing (AM) Applications

The overall goal of this project is to develop an in-process defect monitoring and correction technique for additive manufacturing (AM) of aluminum alloy to improve repeatability for geometric dimensions, material properties, and quality. In Phase I, Sentient collaborated with Johns Hopkins University Applied Physics Lab, and successfully completed all proposed tasks demonstrating two key capabilities: 1) in-situ defect monitoring capability using an infrared (IR) camera, and 2) defect correction capability using optimized AM process parameters through advanced modeling and simulation. The goal of Phase II is to develop the prototype of in-process defect monitoring and correction close-loop feedback system to optimize AM process for flaw control and defect correction. The in-situ defect monitoring capability and advanced simulation capability demonstrated in Phase I will be integrated in Matsuura LUMEX series powder bed fusion platform to demonstrate real-time close-loop feedback control capability. A comprehensive testing (e.g. microstructure, yield strength, fatigue life) will be performed on coupons made by the new AM system to demonstrate the improved part quality compared to baseline properties of as-build AM parts or conventionally sand casted parts. Finally, AM components (i.e. full-size gearbox) will be fabricated using prototype of the new AM system.