Download or read book MONITORING OF METAL ADDITIVE MANUFACTURING VIA OPTICAL EMISSIONS SENSING written by Christopher B. Stutzman and published by . This book was released on 2022 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser-based, metal additive manufacturing (AM) is a growing manufacturing field where complex components are built by through successive laser depositions. Unfortunately these processes are prone to process drifts and flaw formations. Traditional in-situ sensing methods aim to monitor the melt pool to detect process shifts. However, during these processes, a vapor plume is also formed from vaporized material originating in the melt pool. This plume, under certain circumstances, may affect the laser beam and interfere with direct sensing of the melt pool. Therefore this work seeks to confirm that the vapor plume can affect direct imaging of the melt pool, and describe scenarios where the plume can be the sensing target. First, coaxial melt pool images were compared to solidified track geometry and plume camera images. It was determined that coaxial melt pool images do not correlate well to true deposition geometry, and instead appear strongly correlated to plume geometry. Thereafter, experiments were performed to determine the relationship between processing parameters, plume emissions, and build quality using a high-speed, filtered photodiode sensor designed to measure line emissions from the plume. First, single track coupons were deposited with ramped laser power and one of two scan speeds. A linear relationship between plume emissions and laser power was found and a weak relationship with scan speed was found. Next, single tracks were produced under varied gas flow, scan speed, and laser power. It was found that decreasing gas flow leads to brighter emissions, wider track widths, shorter track depths, and an increase in the apparent surface roughness of the coupons. Additionally, cylinders, each one build layer taller than the prior, were deposited under nominal laser power, scan speed, and gas flow conditions to study the effects of hatch angle on optical emissions and coupon geometry. It was found that coupons oscillated between severe overbuilding, and less severe overbuilding with hatch angle. Coupons exhibiting overbuilding (i.e. close to lack-of-fusion) had dimmer optical emissions similar to lack-of-fusion emissions, while coupons less severely overbuild (and one underbuilt) had optical emissions more similar to keyholing. Further, we consider whether optical emissions from the plume can be used to detect laser misalignment in a multi-laser powder bed fusion system. Here we deposit "X" shaped coupons under nominal conditions. Two conditions were tested, one where both legs of the "X" had the same length, and should cause the lasers to meet in the center of the "X" while, the other had one leg shorter and should thus result in one laser leading the other. We found bright emissions occurred when the two lasers coincidentally intersected at the center of the "X" and dimmer emissions in the scenario where one lead the other. Further, we found that, in the non-coincident case, there was an increased time delay between the laser's minimum Euclidean distance and bright emission from the plume. We use this time difference to distinguish between aligned and misaligned coupons. Finally, we deposited several cylindrical coupons at varied laser power, and gas flow speed to replicate process deviations that may occur during the deposition process. Using the optical emission data acquired during the deposition process, a K-nearest neighbors algorithm was fit and estimated the true laser power and gas flow rate during the process. Root mean squared errors for both laser power and gas flow speed predictions were on the order of typical measurement errors. Based on the results of these experiments, recommendations for future research works are thereafter provided.

Download or read book Development of a Spectroscopic Process Monitoring System for Multi laser Metal Powder Bed Fusion Additive Manufacturing written by Andrew Przyjemski and published by . This book was released on 2021 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Multi-laser powder bed fusion additive manufacturing (PBFAM) is the answer to the growing demand for faster and larger part production. However, timely and cost-effective part qualification remains a critical hurdle due to the formation of subsurface flaws during the PBFAM process. Spectroscopic inspired monitoring systems has been shown as a promising technique to detect the presence of flaws using the spectral emissions during the laser welding process. However, the use of spectroscopic sensing in PBFAM systems is complicated by the introduction of multiple simultaneously operating lasers. The work presented in this thesis covers the development of an optical emission spectroscopy inspired, photodiode-based system designed for use in multi-laser PBFAM. The objective of this system is to assist in the real time detection of flaws that form during the PBFAM process.

Download or read book Engineering of Additive Manufacturing Features for Data Driven Solutions written by Mutahar Safdar and published by Springer Nature. This book was released on 2023-06-01 with total page 151 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book is a comprehensive guide to the latest developments in data-driven additive manufacturing (AM). From data mining and pre-processing to signal processing, computer vision, and more, the book covers all the essential techniques for preparing AM data. Readers willl explore the key physical and synthetic sources of AM data throughout the life cycle of the process and learn about feature engineering techniques, pipelines, and resulting features, as well as their applications at each life cycle phase. With a focus on featurization efforts from reviewed literature, this book offers tabular summaries for major data sources and analyzes feature spaces at the design, process, and structure phases of AM to uncover trends and insights specific to feature engineering techniques. Finally, the book discusses current challenges and future directions, including AI/ML/DL readiness of AM data. Whether you're an expert or newcomer to the field, this book provides a broader summary of the status and future of data-driven AM technology.

Download or read book Metal Additive Manufacturing written by Dyuti Sarker and published by John Wiley & Sons. This book was released on 2021-10-26 with total page 624 pages. Available in PDF, EPUB and Kindle. Book excerpt: METAL ADDITIVE MANUFACTURING A comprehensive review of additive manufacturing processes for metallic structures Additive Manufacturing (AM)—also commonly referred to as 3D printing—builds three-dimensional objects by adding materials layer by layer. Recent years have seen unprecedented investment in additive manufacturing research and development by governments and corporations worldwide. This technology has the potential to replace many conventional manufacturing processes, enable the development of new industry practices, and transform the entire manufacturing enterprise. Metal Additive Manufacturing provides an up-to-date review of all essential physics of metal additive manufacturing techniques with emphasis on both laser-based and non-laser-based additive manufacturing processes. This comprehensive volume covers fundamental processes and equipment, governing physics and modelling, design and topology optimization, and more. The text adresses introductory, intermediate, and advanced topics ranging from basic additive manufacturing process classification to practical and material design aspects of additive manufacturability. Written by a panel of expert authors in the field, this authoritative resource: Provides a thorough analysis of AM processes and their theoretical foundations Explains the classification, advantages, and applications of AM processes Describes the equipment required for different AM processes for metallic structures, including laser technologies, positioning devices, feeder and spreader mechanisms, and CAD software Discusses the opportunities, challenges, and current and emerging trends within the field Covers practical considerations, including design for AM, safety, quality assurance, automation, and real-time control of AM processes Includes illustrative cases studies and numerous figures and tables Featuring material drawn from the lead author’s research and professional experience on laser additive manufacturing, Metal Additive Manufacturing is an important source for manufacturing professionals, research and development engineers in the additive industry, and students and researchers involved in mechanical, mechatronics, automatic control, and materials engineering and science.

Download or read book Laser Based Additive Manufacturing of Metal Parts written by Linkan Bian and published by CRC Press. This book was released on 2017-08-09 with total page 328 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser-Based Additive Manufacturing (LBAM) technologies, hailed by some as the "third industrial revolution," can increase product performance, while reducing time-to-market and manufacturing costs. This book is a comprehensive look at new technologies in LBAM of metal parts, covering topics such as mechanical properties, microstructural features, thermal behavior and solidification, process parameters, optimization and control, uncertainty quantification, and more. The book is aimed at addressing the needs of a diverse cross-section of engineers and professionals.

Download or read book Additive Manufacturing Technologies written by Ian Gibson and published by Springer. This book was released on 2014-11-26 with total page 509 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book covers in detail the various aspects of joining materials to form parts. A conceptual overview of rapid prototyping and layered manufacturing is given, beginning with the fundamentals so that readers can get up to speed quickly. Unusual and emerging applications such as micro-scale manufacturing, medical applications, aerospace, and rapid manufacturing are also discussed. This book provides a comprehensive overview of rapid prototyping technologies as well as support technologies such as software systems, vacuum casting, investment casting, plating, infiltration and other systems. This book also: Reflects recent developments and trends and adheres to the ASTM, SI, and other standards Includes chapters on automotive technology, aerospace technology and low-cost AM technologies Provides a broad range of technical questions to ensure comprehensive understanding of the concepts covered

Download or read book Additive Manufacturing written by Pulak Mohan Pandey and published by CRC Press. This book was released on 2023-02-06 with total page 221 pages. Available in PDF, EPUB and Kindle. Book excerpt: The text explores the development, use, and effect of additive manufacturing and digital manufacturing technologies for diverse applications. It will serve as an ideal reference text for graduate students and academic researchers in diverse engineering fields including industrial, manufacturing, and materials science. This book: Discusses the application of 3D virtual models to lasers, electron beams, and computer-controlled additive manufacturing machines Covers applications of additive manufacturing in diverse areas including healthcare, electronics engineering, and production engineering Explains the use of additive manufacturing for biocomposites and functionally graded materials Highlights rapid manufacturing of metallic components using 3D printing Illustrates production and optimization of dental crowns using additive manufacturing This book covers recent developments in manufacturing technology, such as additive manufacturing, 3D printing, rapid prototyping, production process operations, and manufacturing sustainability. The text further emphasizes the use of additive manufacturing for biocomposites and functionally graded materials. It will serve as an ideal reference text for graduate students and academic researchers in the fields of industrial engineering, manufacturing engineering, automotive engineering, aerospace engineering, and materials science.

Download or read book Handbook of Nondestructive Evaluation 4 0 written by Norbert Meyendorf and published by Springer. This book was released on 2022-03-09 with total page 1263 pages. Available in PDF, EPUB and Kindle. Book excerpt: This handbook comprehensively covers the cutting-edge trends and techniques essential for the integration of nondestructive evaluation (NDE) into the changing face of the modern industrial landscape. In particular, it delves into the marriage of NDE with new techniques in e.g. data mining, cloud computing and autonomous operation, highlighting the potential for cyber-physical controlled production and discussing the myriad possible applications across many different industries. The Handbook of NDE 4.0 centers around the Internet of Things and Industry 4.0 – the next generation of industrial production encompassing all aspects of networking across all industrial areas. It discusses the adaptation of existing NDE techniques to emerging new technological areas, such as 3D printing, via the introduction of cyber systems into the inspection and maintenance processes. In addition, the handbook covers topics such as the management and processing of big data with respect to real-time monitoring of structural integrity and reliable inspection of individual components. Remote NDE to include competence not available on-site will be a potential technique to increase reliability of NDE inspections by integrating additional specialist inputs into the decision process by methods such as telepresence, thereby better leveraging the scarce resources of senior inspectors into industrial inspections at multiple sites. The handbook houses a wealth of essential information to help academics, industry professionals and entrepreneurs navigate through this burgeoning new field. The material in this handbook is presented with the intention of ultimately improving human safety through reliable inspections and dependable maintenance of critical infrastructure, while also enhancing business value through reduced downtime, affordable maintenance, and talent optimization.

Download or read book Innovative Lightweight and High Strength Alloys written by Mohammed A. Zikry and published by Elsevier. This book was released on 2024-04-23 with total page 448 pages. Available in PDF, EPUB and Kindle. Book excerpt: Innovative Lightweight and High Strength Alloys: Multiscale Integrated Processing, Experimental, and Modeling Techniques provides multiscale processing, experimental and modeling techniques overviews and perspectives that highlight current roadblocks to optimal design of new alloys alongside solutions. Critical microstructural, chemical and mechanical aspects are considered with techniques for significantly improving mechanical properties. Case studies, applications and hands-on techniques that can be put into immediate practice are included throughout. Sections cover processing techniques for various alloys, including aluminum, titanium, martensitic, austenitic, and others. Additive manufacturing of alloys is also covered, along with updates on mechanical quasi-static, chemically-based, and dynamic experimentation techniques, and more. The book concludes with a modeling section that features several chapters covering multiscale, microstructural, combinatorial computational, and machine learning modeling techniques. - Provides solutions for designing innovative and durable alloys - Demonstrates how to optimally combine alloys with other metallic and non-metallic material systems for longer life cycles and better durability in extreme environments and loading conditions - Outlines a variety of experimentation, characterization and modeling techniques that can be put into immediate practice

Download or read book Fundamentals of Laser Powder Bed Fusion of Metals written by Igor Yadroitsev and published by Elsevier. This book was released on 2021-05-23 with total page 678 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser powder bed fusion of metals is a technology that makes use of a laser beam to selectively melt metal powder layer-by-layer in order to fabricate complex geometries in high performance materials. The technology is currently transforming aerospace and biomedical manufacturing and its adoption is widening into other industries as well, including automotive, energy, and traditional manufacturing. With an increase in design freedom brought to bear by additive manufacturing, new opportunities are emerging for designs not possible previously and in material systems that now provide sufficient performance to be qualified in end-use mission-critical applications. After decades of research and development, laser powder bed fusion is now enabling a new era of digitally driven manufacturing. Fundamentals of Laser Powder Bed Fusion of Metals will provide the fundamental principles in a broad range of topics relating to metal laser powder bed fusion. The target audience includes new users, focusing on graduate and undergraduate students; however, this book can also serve as a reference for experienced users as well, including senior researchers and engineers in industry. The current best practices are discussed in detail, as well as the limitations, challenges, and potential research and commercial opportunities moving forward. - Presents laser powder bed fusion fundamentals, as well as their inherent challenges - Provides an up-to-date summary of this advancing technology and its potential - Provides a comprehensive textbook for universities, as well as a reference for industry - Acts as quick-reference guide

Download or read book Industrializing Additive Manufacturing written by Mirko Meboldt and published by Springer Nature. This book was released on 2020-09-01 with total page 516 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book contains the proceedings of the Additive Manufacturing in Product Development Conference. The content focus on how to support real-world value chains by developing additive manufactured series products.

Download or read book Defect Detection and Monitoring in Metal Additive Manufactured Parts Through Deep Learning of Spatially Resolved Acoustic Spectroscopy Signals written by Jacob Williams and published by . This book was released on 2018 with total page 23 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser powder bed fusion (LPBF) is an additive manufacturing (AM) process that promises to herald a new age in manufacturing by removing many of the design and material-related constraints of traditional subtractive and formative manufacturing processes. However, the level and severity of defects observed in parts produced by the current class of LPBF systems will not be tolerated in safety-critical applications. Hence, there is a need to introduce information-rich process monitoring to assess part integrity simultaneously with fabrication so that opportune corrective action can be taken to minimize part defects. Spatially Resolved Acoustic Spectroscopy (SRAS) is a uniquely positioned nondestructive acoustic microscopy sensing approach that has been successfully used to probe the mechanical properties and assess the presence of defects in LPBF parts. However, the technique is sensitive to extraneous phenomena, such as surface reflectivity, which occur within the LPBF system and may occlude identification of surface breaking and subsurface defects. With a view to applying the SRAS technique for in-process monitoring in a production-scale LPBF environment and to overcome the foregoing challenge, this study proposes the use of a deep learning convolutional neural network that is termed Densely connected Convolutional Block Architecture for Multimodal Image Regression (DCB-MIR), which invokes SRAS-derived acoustic velocity maps of the part as input data and translates them to an output resembling an optical micrograph. Through this approach, we demonstrate that defects, such as porosity and surface imperfections in titanium alloy and nickel alloy specimens made using LPBF, which were not clearly discernable in the as-measured SRAS acoustic map and were obscured by artifacts in the optical image, are accurately identified. To quantify the accuracy of the approach, the cosine similarity between the predicted output images and target optical images was used as the objective function of DCB-MIR. The cosine similarity between the acquired SRAS signatures and the corresponding as-measured optical micrographs of samples typically ranged between -0.15 and 0.15. In contrast, when the optical micrograph-like images derived from DCB-MIR proposed in this work were compared with the optical signatures, the cosine similarity improved in the range of 0.25 to 0.60.

Download or read book Springer Handbook of Additive Manufacturing written by Eujin Pei and published by Springer Nature. This book was released on 2023-11-25 with total page 994 pages. Available in PDF, EPUB and Kindle. Book excerpt: This Handbook is the ultimate definitive guide that covers key fundamentals and advanced applications for Additive Manufacturing. The Handbook has been structured into seven sections, comprising of a thorough Introduction to Additive Manufacturing; Design and Data; Processes; Materials; Post-processing, Testing and Inspection; Education and Training; and Applications and Case Study Examples. The general principles and functional relationships are described in each chapter and supplemented with industry use cases. The aim of this book is to help designers, engineers and manufacturers understand the state-of-the-art developments in the field of Additive Manufacturing. Although this book is primarily aimed at students and educators, it will appeal to researchers and industrial professionals working with technology users, machine or component manufacturers to help them make better decisions in the implementation of Additive Manufacturing and its applications.

Download or read book Additive Manufacturing of Metals written by John O. Milewski and published by Springer. This book was released on 2017-06-28 with total page 351 pages. Available in PDF, EPUB and Kindle. Book excerpt: This engaging volume presents the exciting new technology of additive manufacturing (AM) of metal objects for a broad audience of academic and industry researchers, manufacturing professionals, undergraduate and graduate students, hobbyists, and artists. Innovative applications ranging from rocket nozzles to custom jewelry to medical implants illustrate a new world of freedom in design and fabrication, creating objects otherwise not possible by conventional means. The author describes the various methods and advanced metals used to create high value components, enabling readers to choose which process is best for them. Of particular interest is how harnessing the power of lasers, electron beams, and electric arcs, as directed by advanced computer models, robots, and 3D printing systems, can create otherwise unattainable objects. A timeline depicting the evolution of metalworking, accelerated by the computer and information age, ties AM metal technology to the rapid evolution of global technology trends. Charts, diagrams, and illustrations complement the text to describe the diverse set of technologies brought together in the AM processing of metal. Extensive listing of terms, definitions, and acronyms provides the reader with a quick reference guide to the language of AM metal processing. The book directs the reader to a wealth of internet sites providing further reading and resources, such as vendors and service providers, to jump start those interested in taking the first steps to establishing AM metal capability on whatever scale. The appendix provides hands-on example exercises for those ready to engage in experiential self-directed learning.

Download or read book Theory and Practice of Additive Manufacturing written by Tuhin Mukherjee and published by John Wiley & Sons. This book was released on 2023-09-26 with total page 453 pages. Available in PDF, EPUB and Kindle. Book excerpt: Theory and Practice of Additive Manufacturing Discover the ins and outs of additive manufacturing in this student-friendly textbook Also known as 3D printing, additive manufacturing is a process by which layers of material are added to create three-dimensional objects guided by a digital model. It has revolutionized the design and manufacture of customized products, facilitating the rapid, flexible production of a huge range of goods. It promises to revolutionize manufacturing engineering, shorten industrial supply chains, and more. Theory and Practice of Additive Manufacturing provides the first introduction to this subject designed specifically for students. Balancing the underlying theories behind additive manufacturing with concrete applications, it guides readers through basic processes, essential tools and materials, and more. The result is ideal for readers looking to bring additive manufacturing to bear on engineering or industry careers of almost any kind. Theory and Practice of Additive Manufacturing features: Over 100 worked-out example problems Detailed discussion of the emerging digital tools including mechanistic modeling, machine learning, and more Commitment to pedagogy and reinforcement geared toward student learning outcomes Theory and Practice of Additive Manufacturing is ideal for undergraduate and graduate students and instructors in introductory additive manufacturing courses, as well as practicing engineers and researchers working in industries that use additive manufacturing technologies, including aerospace, automotive, and consumer goods.

Download or read book The Rise of Smart Cities written by Amir Hossein Alavi and published by Butterworth-Heinemann. This book was released on 2022-04-12 with total page 698 pages. Available in PDF, EPUB and Kindle. Book excerpt: The Rise of Smart Cities: Advanced Structural Sensing and Monitoring Systems provides engineers and researchers with a guide to the latest breakthroughs in the deployment of smart sensing and monitoring technologies. The book introduces readers to the latest innovations in the area of smart infrastructure-enabling technologies and howthey can be integrated into the planning and design of smart cities. With this book in hand, readers will find a valuable reference in terms of civil infrastructure health monitoring, advanced sensor network architectures, smart sensing materials, multifunctional material and structures, crowdsourced/social sensing, remote sensing and aerial sensing, and advanced computation in sensornetworks. - Reviews the latest development in smart structural health monitoring (SHM) systems - Introduces all major algorithms, with a focus on practical implementation - Includes real-world applications and case studies - Opens up a new horizon for robust structural sensing methods and their applications in smart cities

Download or read book Additive Manufacturing of High Performance Metallic Materials written by Robert Pederson and published by Elsevier. This book was released on 2023-09-19 with total page 580 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive Manufacturing of High-Performance Metallic Materials outlines the state-of-the-art on AM in high performance materials utilizing the two most industrially interesting routes of powder bed fusion (PBF) and directed energy deposition (DED). The book delves into Feedstock, Processing, Monitoring and control, Modeling and simulation, and Surface and thermal post-treatments. It specifically addresses materials and the most relevant and high performance applications, namely Ni-based alloys and Titanium alloys, and also provides insights into potential applications through illustrative case studies. With each chapter contributed by experts in the field, this work will serve as a comprehensive resource for graduate students and practitioners alike. - Covers the entire value chain relevant to additive manufacturing spanning feedstock, processing, monitoring, post-treatment, testing and applications - Includes the fundamental understanding of varied associated aspects derived from both extensive experimental knowledge and theoretical investigations - Addresses key materials relevant to varied high performance applications, namely Superalloys and Ni-based alloys