Accelerating large-format metal additive manufacturing: How controls R&D is driving speed, scale, and efficiency

Brian T. Gibson; Paritosh Mhatre; Michael C. Borish; Justin L. West; Emma D. Betters; Scott S. Smith; Bradley S. Richardson; Lonnie J. Love; Tayler W. Sundermann; John T. Potter; Emma J. Vetland; William C. Henry; Christopher P. Allison

doi:10.1115/IMECE2020-23322

Accelerating large-format metal additive manufacturing: How controls R&D is driving speed, scale, and efficiency

Brian T. Gibson, Paritosh Mhatre, Michael C. Borish, Justin L. West, Emma D. Betters, Scott S. Smith, Bradley S. Richardson, Lonnie J. Love, Tayler W. Sundermann, John T. Potter, Emma J. Vetland, William C. Henry, Christopher P. Allison

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

3 Scopus citations

Abstract

This article highlights work at Oak Ridge NationalLaboratory's Manufacturing Demonstration Facility to developclosed-loop, feedback control for laser-wire based DirectedEnergy Deposition, a form of metal Big Area AdditiveManufacturing (m-BAAM), a process being developed inpartnership with GKN Aerospace specifically for the productionof Ti-6Al-4V pre-forms for aerospace components. A large-scalestructural demonstrator component is presented as a case-studyin which not just control, but the entire 3D printing workflow form-BAAM is discussed in detail, including design principles forlarge-format metal AM, toolpath generation, parameterdevelopment, process control, and system operation, as well aspost-print net-shape geometric analysis and finish machining. Interms of control, a multi-sensor approach has been utilized tomeasure both layer height and melt pool size, and multiple modesof closed-loop control have been developed to manipulateprocess parameters (laser power, print speed, deposition rate) tocontrol these variables. Layer height control and melt pool sizecontrol have yielded excellent local (intralayer) and global(component-level) geometry control, and the impact of melt poolsize control in particular on thermal gradients and materialproperties is the subject of continuing research. Further, thesemodes of control have allowed the process to advance to higherdeposition rates (exceeding 7.5 lb/hr), larger parts (1-meterscale), shorter build times, and higher overall efficiency. Thecontrol modes are examined individually, highlighting their development, demonstration, and lessons learned, and it isshown how they operate concurrently to enable the printing of alarge-scale, near net shape Ti-6Al-4V component.

Original language	English
Title of host publication	Advanced Manufacturing
Publisher	American Society of Mechanical Engineers (ASME)
ISBN (Electronic)	9780791884485
DOIs	https://doi.org/10.1115/IMECE2020-23322
State	Published - 2020
Event	ASME 2020 International Mechanical Engineering Congress and Exposition, IMECE 2020 - Virtual, Online Duration: Nov 16 2020 → Nov 19 2020

Publication series

Name	ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE)
Volume	2A-2020

Conference

Conference	ASME 2020 International Mechanical Engineering Congress and Exposition, IMECE 2020
City	Virtual, Online
Period	11/16/20 → 11/19/20

Funding

This manuscript has been authored by UT-Battelle, LLC under contract no. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States government retains and the publisher, by accepting the article for publication, acknowledges that the United States government retains a non-exclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE public access plan (http://energy.gov/downloads/doe-public-access-plan). This research was funded by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office in partnership with GKN Aerospace. The authors would also like to acknowledge the contributions of the broader Oak Ridge National Laboratory and GKN Aerospace teams, including Alex Roschli and Brian Post of ORNL, and Aaron Thornton and Jeremy Tylenda of GKN Aerospace.

Keywords

3D Printing
Additive Manufacturing
Control
Metal

Access to Document

10.1115/IMECE2020-23322

Cite this

Gibson, B. T., Mhatre, P., Borish, M. C., West, J. L., Betters, E. D., Smith, S. S., Richardson, B. S., Love, L. J., Sundermann, T. W., Potter, J. T., Vetland, E. J., Henry, W. C., & Allison, C. P. (2020). Accelerating large-format metal additive manufacturing: How controls R&D is driving speed, scale, and efficiency. In Advanced Manufacturing Article V02AT02A038 (ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE); Vol. 2A-2020). American Society of Mechanical Engineers (ASME). https://doi.org/10.1115/IMECE2020-23322

@inproceedings{eaa6d9687bd0413f9fc209688918c44e,

title = "Accelerating large-format metal additive manufacturing: How controls R&D is driving speed, scale, and efficiency",

abstract = "This article highlights work at Oak Ridge NationalLaboratory's Manufacturing Demonstration Facility to developclosed-loop, feedback control for laser-wire based DirectedEnergy Deposition, a form of metal Big Area AdditiveManufacturing (m-BAAM), a process being developed inpartnership with GKN Aerospace specifically for the productionof Ti-6Al-4V pre-forms for aerospace components. A large-scalestructural demonstrator component is presented as a case-studyin which not just control, but the entire 3D printing workflow form-BAAM is discussed in detail, including design principles forlarge-format metal AM, toolpath generation, parameterdevelopment, process control, and system operation, as well aspost-print net-shape geometric analysis and finish machining. Interms of control, a multi-sensor approach has been utilized tomeasure both layer height and melt pool size, and multiple modesof closed-loop control have been developed to manipulateprocess parameters (laser power, print speed, deposition rate) tocontrol these variables. Layer height control and melt pool sizecontrol have yielded excellent local (intralayer) and global(component-level) geometry control, and the impact of melt poolsize control in particular on thermal gradients and materialproperties is the subject of continuing research. Further, thesemodes of control have allowed the process to advance to higherdeposition rates (exceeding 7.5 lb/hr), larger parts (1-meterscale), shorter build times, and higher overall efficiency. Thecontrol modes are examined individually, highlighting their development, demonstration, and lessons learned, and it isshown how they operate concurrently to enable the printing of alarge-scale, near net shape Ti-6Al-4V component.",

keywords = "3D Printing, Additive Manufacturing, Control, Metal",

author = "Gibson, {Brian T.} and Paritosh Mhatre and Borish, {Michael C.} and West, {Justin L.} and Betters, {Emma D.} and Smith, {Scott S.} and Richardson, {Bradley S.} and Love, {Lonnie J.} and Sundermann, {Tayler W.} and Potter, {John T.} and Vetland, {Emma J.} and Henry, {William C.} and Allison, {Christopher P.}",

note = "Publisher Copyright: {\textcopyright} 2020 American Society of Mechanical Engineers (ASME). All rights reserved.; ASME 2020 International Mechanical Engineering Congress and Exposition, IMECE 2020 ; Conference date: 16-11-2020 Through 19-11-2020",

year = "2020",

doi = "10.1115/IMECE2020-23322",

language = "English",

series = "ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE)",

publisher = "American Society of Mechanical Engineers (ASME)",

booktitle = "Advanced Manufacturing",

}

Gibson, BT , Mhatre, P , Borish, MC , West, JL , Betters, ED , Smith, SS, Richardson, BS, Love, LJ, Sundermann, TW, Potter, JT, Vetland, EJ, Henry, WC & Allison, CP 2020, Accelerating large-format metal additive manufacturing: How controls R&D is driving speed, scale, and efficiency. in Advanced Manufacturing., V02AT02A038, ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE), vol. 2A-2020, American Society of Mechanical Engineers (ASME), ASME 2020 International Mechanical Engineering Congress and Exposition, IMECE 2020, Virtual, Online, 11/16/20. https://doi.org/10.1115/IMECE2020-23322

Accelerating large-format metal additive manufacturing: How controls R&D is driving speed, scale, and efficiency. / Gibson, Brian T.; Mhatre, Paritosh ; Borish, Michael C. et al.
Advanced Manufacturing. American Society of Mechanical Engineers (ASME), 2020. V02AT02A038 (ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE); Vol. 2A-2020).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

TY - GEN

T1 - Accelerating large-format metal additive manufacturing

T2 - ASME 2020 International Mechanical Engineering Congress and Exposition, IMECE 2020

AU - Gibson, Brian T.

AU - Mhatre, Paritosh

AU - Borish, Michael C.

AU - West, Justin L.

AU - Betters, Emma D.

AU - Smith, Scott S.

AU - Richardson, Bradley S.

AU - Love, Lonnie J.

AU - Sundermann, Tayler W.

AU - Potter, John T.

AU - Vetland, Emma J.

AU - Henry, William C.

AU - Allison, Christopher P.

PY - 2020

Y1 - 2020

N2 - This article highlights work at Oak Ridge NationalLaboratory's Manufacturing Demonstration Facility to developclosed-loop, feedback control for laser-wire based DirectedEnergy Deposition, a form of metal Big Area AdditiveManufacturing (m-BAAM), a process being developed inpartnership with GKN Aerospace specifically for the productionof Ti-6Al-4V pre-forms for aerospace components. A large-scalestructural demonstrator component is presented as a case-studyin which not just control, but the entire 3D printing workflow form-BAAM is discussed in detail, including design principles forlarge-format metal AM, toolpath generation, parameterdevelopment, process control, and system operation, as well aspost-print net-shape geometric analysis and finish machining. Interms of control, a multi-sensor approach has been utilized tomeasure both layer height and melt pool size, and multiple modesof closed-loop control have been developed to manipulateprocess parameters (laser power, print speed, deposition rate) tocontrol these variables. Layer height control and melt pool sizecontrol have yielded excellent local (intralayer) and global(component-level) geometry control, and the impact of melt poolsize control in particular on thermal gradients and materialproperties is the subject of continuing research. Further, thesemodes of control have allowed the process to advance to higherdeposition rates (exceeding 7.5 lb/hr), larger parts (1-meterscale), shorter build times, and higher overall efficiency. Thecontrol modes are examined individually, highlighting their development, demonstration, and lessons learned, and it isshown how they operate concurrently to enable the printing of alarge-scale, near net shape Ti-6Al-4V component.

AB - This article highlights work at Oak Ridge NationalLaboratory's Manufacturing Demonstration Facility to developclosed-loop, feedback control for laser-wire based DirectedEnergy Deposition, a form of metal Big Area AdditiveManufacturing (m-BAAM), a process being developed inpartnership with GKN Aerospace specifically for the productionof Ti-6Al-4V pre-forms for aerospace components. A large-scalestructural demonstrator component is presented as a case-studyin which not just control, but the entire 3D printing workflow form-BAAM is discussed in detail, including design principles forlarge-format metal AM, toolpath generation, parameterdevelopment, process control, and system operation, as well aspost-print net-shape geometric analysis and finish machining. Interms of control, a multi-sensor approach has been utilized tomeasure both layer height and melt pool size, and multiple modesof closed-loop control have been developed to manipulateprocess parameters (laser power, print speed, deposition rate) tocontrol these variables. Layer height control and melt pool sizecontrol have yielded excellent local (intralayer) and global(component-level) geometry control, and the impact of melt poolsize control in particular on thermal gradients and materialproperties is the subject of continuing research. Further, thesemodes of control have allowed the process to advance to higherdeposition rates (exceeding 7.5 lb/hr), larger parts (1-meterscale), shorter build times, and higher overall efficiency. Thecontrol modes are examined individually, highlighting their development, demonstration, and lessons learned, and it isshown how they operate concurrently to enable the printing of alarge-scale, near net shape Ti-6Al-4V component.

KW - 3D Printing

KW - Additive Manufacturing

KW - Control

KW - Metal

UR - http://www.scopus.com/inward/record.url?scp=85101288256&partnerID=8YFLogxK

U2 - 10.1115/IMECE2020-23322

DO - 10.1115/IMECE2020-23322

M3 - Conference contribution

AN - SCOPUS:85101288256

T3 - ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE)

BT - Advanced Manufacturing

PB - American Society of Mechanical Engineers (ASME)

Y2 - 16 November 2020 through 19 November 2020

ER -

Gibson BT , Mhatre P , Borish MC , West JL , Betters ED , Smith SS et al. Accelerating large-format metal additive manufacturing: How controls R&D is driving speed, scale, and efficiency. In Advanced Manufacturing. American Society of Mechanical Engineers (ASME). 2020. V02AT02A038. (ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE)). doi: 10.1115/IMECE2020-23322

Accelerating large-format metal additive manufacturing: How controls R&D is driving speed, scale, and efficiency

Abstract

Publication series

Conference

Funding

Keywords

Access to Document

Other files and links

Fingerprint

Cite this