Sensing for directed energy deposition and powder bed fusion additive manufacturing at Penn State University

Abdalla Ramadan Nassar, Edward William Reutzel, Stephen W. Brown, John P. Morgan, Jacob P. Morgan, Donald J. Natale, Rick L. Tutwiler, David P. Feck, Jeffery C. Banks

Research output: Chapter in Book/Report/Conference proceedingConference contribution

7 Citations (Scopus)

Abstract

Additive manufacturing of metal components through directed energy deposition or powder bed fusion is a complex undertaking, often involving hundreds or thousands of individual laser deposits. During processing, conditions may fluctuate, e.g. material feed rate, beam power, surrounding gas composition, local and global temperature, build geometry, etc., leading to unintended variations in final part geometry, microstructure and properties. To assess or control as-deposited quality, researchers have used a variety of methods, including those based on sensing of melt pool and plume emission characteristics, characteristics of powder application, and layer-wise imaging. Here, a summary of ongoing process monitoring activities at Penn State is provided, along with a discussion of recent advancements in the area of layer-wise image acquisition and analysis during powder bed fusion processing. Specifically, methods that enable direct comparisons of CAD model, build images, and 3D micro-tomographic scan data will be covered, along with thoughts on how such analyses can be related to overall process quality.

Original languageEnglish (US)
Title of host publicationLaser 3D Manufacturing III
EditorsAlberto Pique, Bo Gu, Henry Helvajian
PublisherSPIE
ISBN (Electronic)9781628419733
DOIs
StatePublished - Jan 1 2016
EventLaser 3D Manufacturing III - San Francisco, United States
Duration: Feb 15 2016Feb 18 2016

Publication series

NameProceedings of SPIE - The International Society for Optical Engineering
Volume9738
ISSN (Print)0277-786X
ISSN (Electronic)1996-756X

Other

OtherLaser 3D Manufacturing III
CountryUnited States
CitySan Francisco
Period2/15/162/18/16

Fingerprint

3D printers
Powder
Powders
beds
Fusion
Sensing
Fusion reactions
manufacturing
Manufacturing
fusion
Energy
Process Monitoring
Geometry
Image Acquisition
Image acquisition
Process monitoring
gas composition
computer aided design
Processing
geometry

All Science Journal Classification (ASJC) codes

  • Electronic, Optical and Magnetic Materials
  • Condensed Matter Physics
  • Computer Science Applications
  • Applied Mathematics
  • Electrical and Electronic Engineering

Cite this

Nassar, A. R., Reutzel, E. W., Brown, S. W., Morgan, J. P., Morgan, J. P., Natale, D. J., ... Banks, J. C. (2016). Sensing for directed energy deposition and powder bed fusion additive manufacturing at Penn State University. In A. Pique, B. Gu, & H. Helvajian (Eds.), Laser 3D Manufacturing III [97380R] (Proceedings of SPIE - The International Society for Optical Engineering; Vol. 9738). SPIE. https://doi.org/10.1117/12.2217855
Nassar, Abdalla Ramadan ; Reutzel, Edward William ; Brown, Stephen W. ; Morgan, John P. ; Morgan, Jacob P. ; Natale, Donald J. ; Tutwiler, Rick L. ; Feck, David P. ; Banks, Jeffery C. / Sensing for directed energy deposition and powder bed fusion additive manufacturing at Penn State University. Laser 3D Manufacturing III. editor / Alberto Pique ; Bo Gu ; Henry Helvajian. SPIE, 2016. (Proceedings of SPIE - The International Society for Optical Engineering).
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abstract = "Additive manufacturing of metal components through directed energy deposition or powder bed fusion is a complex undertaking, often involving hundreds or thousands of individual laser deposits. During processing, conditions may fluctuate, e.g. material feed rate, beam power, surrounding gas composition, local and global temperature, build geometry, etc., leading to unintended variations in final part geometry, microstructure and properties. To assess or control as-deposited quality, researchers have used a variety of methods, including those based on sensing of melt pool and plume emission characteristics, characteristics of powder application, and layer-wise imaging. Here, a summary of ongoing process monitoring activities at Penn State is provided, along with a discussion of recent advancements in the area of layer-wise image acquisition and analysis during powder bed fusion processing. Specifically, methods that enable direct comparisons of CAD model, build images, and 3D micro-tomographic scan data will be covered, along with thoughts on how such analyses can be related to overall process quality.",
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Nassar, AR, Reutzel, EW, Brown, SW, Morgan, JP, Morgan, JP, Natale, DJ, Tutwiler, RL, Feck, DP & Banks, JC 2016, Sensing for directed energy deposition and powder bed fusion additive manufacturing at Penn State University. in A Pique, B Gu & H Helvajian (eds), Laser 3D Manufacturing III., 97380R, Proceedings of SPIE - The International Society for Optical Engineering, vol. 9738, SPIE, Laser 3D Manufacturing III, San Francisco, United States, 2/15/16. https://doi.org/10.1117/12.2217855

Sensing for directed energy deposition and powder bed fusion additive manufacturing at Penn State University. / Nassar, Abdalla Ramadan; Reutzel, Edward William; Brown, Stephen W.; Morgan, John P.; Morgan, Jacob P.; Natale, Donald J.; Tutwiler, Rick L.; Feck, David P.; Banks, Jeffery C.

Laser 3D Manufacturing III. ed. / Alberto Pique; Bo Gu; Henry Helvajian. SPIE, 2016. 97380R (Proceedings of SPIE - The International Society for Optical Engineering; Vol. 9738).

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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Nassar AR, Reutzel EW, Brown SW, Morgan JP, Morgan JP, Natale DJ et al. Sensing for directed energy deposition and powder bed fusion additive manufacturing at Penn State University. In Pique A, Gu B, Helvajian H, editors, Laser 3D Manufacturing III. SPIE. 2016. 97380R. (Proceedings of SPIE - The International Society for Optical Engineering). https://doi.org/10.1117/12.2217855