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Showing 1 to 20 of 42 for “"metal additive manufacturing"”.
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Qualification and characterization of metal additive manufacturing
Additive manufacturing (AM) has emerged as an effective and efficient way to digitally manufacture complicated structures. Raytheon Missile Systems seeks to gain limited production capability with metals AM, which can only be achieved with qualified, predictable processes that reduce variation. The …
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Scaling Metal Additive Manufacturing from R&D to Production
Metal additive manufacturing (AM) has been successfully commercialized, yet widespread adoption has not been achieved so far. This is partly because companies struggle to operate AM factories profitably and efficiently at industrial scale. This thesis proposes a data strategy to address this …
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Physics-informed Machine Learning for Digital Twins of Metal Additive Manufacturing
Metal additive manufacturing (AM) is an emerging technology for producing parts with virtually no constraint on the geometry. AM builds a part by depositing materials in a layer-by-layer fashion. Despite the benefits in several critical applications, quality issues are one of the primary concerns …
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Sources of Quality Uncertainty in Laser Powder Bed Fusion Metal Additive Manufacturing
<p>"Powder based additive manufacturing (AM) exhibits tremendous uncertainties, where variations in build quality is present despite utilizing similar build processing parameters. First, this work reports the features and formation mechanisms of five unique types of spatter during the LPBF process …
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Multi-Physics Sensing and Real-time Quality Control in Metal Additive Manufacturing
… is one of the most effective ways to achieve metal additive manufacturing. However, this method still suffers from deformation, delamination, dimensional error, and porosities. One of the most significant issues is poor printing accuracy, especially for small features such as turbine blade …
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Material and process development for material extrusion metal additive manufacturing using recycled nickel
Metal Extrusion 3D-printing is a cost-effective alternative to powder bed fusion for producing metal parts, but limited material compatibility with this technique and reliance on virgin resources hinder wider adoption and raise sustainability concerns due to the depletion of natural resources. This …
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Born Qualified Additive Manufacturing: In-situ Part Quality Assurance in Metal Additive Manufacturing
… assurance methodologies for parts made using metal additive manufacturing (AM). Additive manufacturing is becoming a prominent manufacturing process due to its ability to generate complex structures that would otherwise be impossible to produce using traditional machining. This freedom of …
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Smart Process Design with Machine Learning for Quality Assurance in Metal Additive Manufacturing
Additive Manufacturing (AM), particularly Laser Powder Bed Fusion (LPBF), has revolutionized the fabrication of complex metal components through its layer-by-layer construction capability. However, the widespread adoption of LPBF remains limited by recurring defects such as porosity, residual …
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Testbeds for quality and porosity control in metal additive manufacturing by selective laser melting
Selective laser melting (SLM) is a metal additive manufacturing process that can achieve high local density and near-net shape geometric accuracy. The dynamics of the meltpool and stability of the melt track upon cooling are critical to the microstructure, porosity, and final properties of the …
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Design and Fabrication of an Oscillating Tool for Powder Spreading in Metal Additive Manufacturing
Powder spreading methods for metal additive manufacturing processes, such as laser powder bed fusion and binder jetting, are intended to produce thin, dense, and uniform powder layers in order for finished parts to have satisfactory material and mechanical properties. The spreading of fine powders …
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A hybrid physics-based/data-driven computational framework for multi-physics modeling of metal additive manufacturing
Submission published under a 24 month embargo labeled 'U of I Access', the embargo will last until 2025-05-01
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Powder Bed Surface Quality and Particle Size Distribution for Metal Additive Manufacturing and Comparison with Discrete Element Model
<p>Metal additive manufacturing (AM) can produce complex parts that were once considered impossible or too costly to fabricate using conventional machining techniques, making AM machines an exceptional tool for rapid prototyping, one-off parts, and labor-intensive geometries. Due to the growing …
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Electroforming of personalized miniature metal parts using additively manufactured molds
In response to evolving manufacturing trends favoring personalized, small-batch production, this thesis centers on the development of additively manufactured molds to facilitate the electroforming of personalized metal parts. The methodology encompasses standardized mold design, experimental …
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Discrete Particle Dynamics Models: Computational Aspects And Applications
… policy design, (b) powder spread modeling for metal additive manufacturing design, and (c) energy characterization of nanomaterials modified fiber-reinforced composite for interface design. All these problems require large computational resources to parametrically address inherent …
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Development of in-situ radiometric inspection methods for quality assurance in laser powder bed fusion
<p>“Laser Powder Bed Fusion (LPBF) metal Additive Manufacturing (AM) fabricates 3D metal parts layer-by-layer. The process enables production of geometrically complex parts that are difficult to inspect with traditional methods. The LPBF parts experience significant geometry driven thermal …
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Microstructure Representation and Prediction via Convolutional Neural Network-Based Texture Representation and Synthesis, Towards Process Structure Linkage
Metal additive manufacturing (AM) provides a platform for microstructure optimization via process control, the ability to model the evolution of microstructures from changes in processing condition or even predict the microstructures from given processing condition would greatly reduce the time …
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Engineering Anisotropic Porosity in Green Parts from Binder Jet 3D Printing
<p>Binder Jet Additive Manufacturing (BJAM) is a promising metal additive manufacturing technique that enables the fabrication of complex geometries without the need for support structures. However, the inherent porosity in green parts, remains a challenge in achieving desired mechanical properties …
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Custom-Engineered and Additively Manufactured Components for Strengthening Steel Bridges
… of reconstructed corrosion geometries with metal additive manufacturing to produce custom-engineered repair components that match the exact loss profle, providing a targeted alternative to conventional plate repairs. The fnal contribution is the numerical and experimental validation of the …
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Impact and melting dynamics of micron-sized particles on a liquid pool
… during direct energy deposition, a form of metal additive manufacturing. In this work, an organic transparent model system was designed, in which impact and subsequent melting of paraffin wax particles (melting point: ≈60°C, diameter: 200-800 μm, impact velocity: 0.3-1.9 m/s) onto a pool of …
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Directed Energy Deposition Additive Manufacturing Supplier Sourcing for Aerospace
… weight on the aircraft. P&W has been utilizing Additive Manufacturing (AM) for rapid prototyping and Research & Development (R&D) cost reduction for three decades. However, most of the past metal additive manufacturing applications have utilized Powder Bed Fusion technology, which has limited …
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