Melt pool monitoring for control and data analytics in large-scale metal additive manufacturing

B. T. Gibson; Y. K. Bandari; B. S. Richardson; A. C. Roschli; B. K. Post; M. C. Borish; A. Thornton; W. C. Henry; M. Lamsey; L. J. Love

Melt pool monitoring for control and data analytics in large-scale metal additive manufacturing

B. T. Gibson, Y. K. Bandari, B. S. Richardson, A. C. Roschli, B. K. Post, M. C. Borish, A. Thornton, W. C. Henry, M. Lamsey, L. J. Love

Research output: Contribution to conference › Paper › peer-review

7 Scopus citations

Abstract

Laser-wire based Directed Energy Deposition (DED) processes are being developed at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility, in collaboration with GKN Aerospace, for large volume metal additive manufacturing of metallic structures. The technology has the potential to deliver reduced costs and lead times when compared to conventional methods of manufacturing in several industries. While complex structures are being produced with relatively high deposition rates and at near-net shape, issues persist with achieving consistent geometric accuracy and thermal stability. A significant research effort is focused on developing coordinated, multi-modal sensing and control for addressing these issues. An introduction to this large-volume metal process will be provided, followed by investigations into real-time thermal monitoring capabilities that support control and data analytics frameworks. Studies focused on melt pool monitoring via infrared thermography, thermal and geometric effects on melt pool size measurement, and interactions between process variables and thermal monitoring metrics are presented.

Original language	English
Pages	1411-1429
Number of pages	19
State	Published - 2019
Event	30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019 - Austin, United States Duration: Aug 12 2019 → Aug 14 2019

Conference

Conference	30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019
Country/Territory	United States
City	Austin
Period	08/12/19 → 08/14/19

Funding

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 gratefully acknowledge the extended Oak Ridge National Laboratory and GKN Aerospace teams that contributed to this work, including John Potter, Ronnie Wilson, and Chris Allison of GKN, as well as Abigail Barnes and Katherine Gaul of ORNL for manuscript review and editing. The authors also acknowledge Steffen Bonss of Laserline and Sandro Mehner of Fraunhofer USA for their advice and technical assistance.

Funders	Funder number
U.S. Department of Energy
Advanced Manufacturing Office
Office of Energy Efficiency and Renewable Energy

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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Gibson, B. T., Bandari, Y. K., Richardson, B. S., Roschli, A. C., Post, B. K., Borish, M. C., Thornton, A., Henry, W. C., Lamsey, M., & Love, L. J. (2019). Melt pool monitoring for control and data analytics in large-scale metal additive manufacturing. 1411-1429. Paper presented at 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019, Austin, United States.

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title = "Melt pool monitoring for control and data analytics in large-scale metal additive manufacturing",

abstract = "Laser-wire based Directed Energy Deposition (DED) processes are being developed at Oak Ridge National Laboratory{\textquoteright}s Manufacturing Demonstration Facility, in collaboration with GKN Aerospace, for large volume metal additive manufacturing of metallic structures. The technology has the potential to deliver reduced costs and lead times when compared to conventional methods of manufacturing in several industries. While complex structures are being produced with relatively high deposition rates and at near-net shape, issues persist with achieving consistent geometric accuracy and thermal stability. A significant research effort is focused on developing coordinated, multi-modal sensing and control for addressing these issues. An introduction to this large-volume metal process will be provided, followed by investigations into real-time thermal monitoring capabilities that support control and data analytics frameworks. Studies focused on melt pool monitoring via infrared thermography, thermal and geometric effects on melt pool size measurement, and interactions between process variables and thermal monitoring metrics are presented.",

author = "Gibson, {B. T.} and Bandari, {Y. K.} and Richardson, {B. S.} and Roschli, {A. C.} and Post, {B. K.} and Borish, {M. C.} and A. Thornton and Henry, {W. C.} and M. Lamsey and Love, {L. J.}",

note = "Publisher Copyright: {\textcopyright} Solid Freeform Fabrication 2019: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019. All rights reserved.; 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019 ; Conference date: 12-08-2019 Through 14-08-2019",

year = "2019",

language = "English",

pages = "1411--1429",

}

Gibson, BT, Bandari, YK, Richardson, BS, Roschli, AC , Post, BK , Borish, MC, Thornton, A, Henry, WC, Lamsey, M & Love, LJ 2019, 'Melt pool monitoring for control and data analytics in large-scale metal additive manufacturing', Paper presented at 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019, Austin, United States, 08/12/19 - 08/14/19 pp. 1411-1429.

Melt pool monitoring for control and data analytics in large-scale metal additive manufacturing. / Gibson, B. T.; Bandari, Y. K.; Richardson, B. S. et al.
2019. 1411-1429 Paper presented at 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019, Austin, United States.

Research output: Contribution to conference › Paper › peer-review

TY - CONF

T1 - Melt pool monitoring for control and data analytics in large-scale metal additive manufacturing

AU - Gibson, B. T.

AU - Bandari, Y. K.

AU - Richardson, B. S.

AU - Roschli, A. C.

AU - Post, B. K.

AU - Borish, M. C.

AU - Thornton, A.

AU - Henry, W. C.

AU - Lamsey, M.

AU - Love, L. J.

N1 - Publisher Copyright: © Solid Freeform Fabrication 2019: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019. All rights reserved.

PY - 2019

Y1 - 2019

N2 - Laser-wire based Directed Energy Deposition (DED) processes are being developed at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility, in collaboration with GKN Aerospace, for large volume metal additive manufacturing of metallic structures. The technology has the potential to deliver reduced costs and lead times when compared to conventional methods of manufacturing in several industries. While complex structures are being produced with relatively high deposition rates and at near-net shape, issues persist with achieving consistent geometric accuracy and thermal stability. A significant research effort is focused on developing coordinated, multi-modal sensing and control for addressing these issues. An introduction to this large-volume metal process will be provided, followed by investigations into real-time thermal monitoring capabilities that support control and data analytics frameworks. Studies focused on melt pool monitoring via infrared thermography, thermal and geometric effects on melt pool size measurement, and interactions between process variables and thermal monitoring metrics are presented.

AB - Laser-wire based Directed Energy Deposition (DED) processes are being developed at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility, in collaboration with GKN Aerospace, for large volume metal additive manufacturing of metallic structures. The technology has the potential to deliver reduced costs and lead times when compared to conventional methods of manufacturing in several industries. While complex structures are being produced with relatively high deposition rates and at near-net shape, issues persist with achieving consistent geometric accuracy and thermal stability. A significant research effort is focused on developing coordinated, multi-modal sensing and control for addressing these issues. An introduction to this large-volume metal process will be provided, followed by investigations into real-time thermal monitoring capabilities that support control and data analytics frameworks. Studies focused on melt pool monitoring via infrared thermography, thermal and geometric effects on melt pool size measurement, and interactions between process variables and thermal monitoring metrics are presented.

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M3 - Paper

AN - SCOPUS:85095978767

SP - 1411

EP - 1429

T2 - 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019

Y2 - 12 August 2019 through 14 August 2019

ER -

Melt pool monitoring for control and data analytics in large-scale metal additive manufacturing

Abstract

Conference

Funding

UN SDGs

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