H. S. Dhami, Pritish Panda, Puli Saikiran, Richie Garg, Koushik Viswanathan
{"title":"A sensing integrated metal additive manufacturing platform for exploring the use of non-standard powders","authors":"H. S. Dhami, Pritish Panda, Puli Saikiran, Richie Garg, Koushik Viswanathan","doi":"10.1115/1.4064157","DOIUrl":null,"url":null,"abstract":"Research applications that rely on commercial directed energy deposition (DED) based metal additive manufacturing systems are commonly constrained by their inflexibility in handling various non-standard powders, lack of fine system control and inherent difficulty with sensor integration. In this work, we present the design of a sensing-integrated platform for metal additive manufacturing. A modular design allows easy modification of specific sub-systems, such as laser integration or powder delivery mechanisms, to enable capabilities that are difficult to realize with commercial systems. As an example, we demonstrate DED performance using non-conventional inexpensive powders produced via abrasion and water atomization techniques. System performance is evaluated using integrated sensors and complemented by numerical/ analytical calculations. Based on these results, a nominal operation map combining thermal field with powder flow is generated for determining process parameters suitable for a given material/build combination and can be generally applicable for any DED AM system. In addition to handling non-spherical and alternatively sourced powders, the system capabilities for printing multi-material complex contours are demonstrated.","PeriodicalId":507815,"journal":{"name":"Journal of Manufacturing Science and Engineering","volume":null,"pages":null},"PeriodicalIF":0.0000,"publicationDate":"2023-11-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Manufacturing Science and Engineering","FirstCategoryId":"1085","ListUrlMain":"https://doi.org/10.1115/1.4064157","RegionNum":0,"RegionCategory":null,"ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"","JCRName":"","Score":null,"Total":0}
引用次数: 0
Abstract
Research applications that rely on commercial directed energy deposition (DED) based metal additive manufacturing systems are commonly constrained by their inflexibility in handling various non-standard powders, lack of fine system control and inherent difficulty with sensor integration. In this work, we present the design of a sensing-integrated platform for metal additive manufacturing. A modular design allows easy modification of specific sub-systems, such as laser integration or powder delivery mechanisms, to enable capabilities that are difficult to realize with commercial systems. As an example, we demonstrate DED performance using non-conventional inexpensive powders produced via abrasion and water atomization techniques. System performance is evaluated using integrated sensors and complemented by numerical/ analytical calculations. Based on these results, a nominal operation map combining thermal field with powder flow is generated for determining process parameters suitable for a given material/build combination and can be generally applicable for any DED AM system. In addition to handling non-spherical and alternatively sourced powders, the system capabilities for printing multi-material complex contours are demonstrated.