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Project

Non-destructive in-process monitoring strategies for metal additive manufacturing (FWOTM854)

Metal additive manufacturing (AM), more commonly known as 3D printing, introduces the “imagination is the limit”- concept to the manufacturing landscape: building layer by layer, the technique can construct components with highly complex geometries from almost any digital model. This creates interesting opportunities in a wide range of applications, but intrinsic quality problems prevent the technology from fully infusing into the industry.

The key to overcome this hurdle is to develop strategies for the detection of manufacturing defects during the printing process itself. Not only is this more convenient than having to inspect the complex structures post-build, but detecting flaws during the production allows for a dynamic intervention mechanism and minimal losses.

The aim of this research is to develop and validate at least two “in-process” non-destructive inspection methods for metal AM by laser metal deposition, both of which are built upon the expertise of the Acoustics and Vibration Research Group: IR thermography and laser ultrasonic testing. These technologies will be studied for their capability to detect internal defects as well as residual stresses, and the results will be used to calibrate numerical models and optimize the inspection process. The developed “in-process” monitoring technologies will finally be implemented and validated on the beyond state-of-the-art HyLaForm research platform, a hybrid laser-based additive-subtractive 3D printer.
Date:1 Oct 2017 →  1 Jun 2019
Keywords:Metal additive manufacturing, 3D printing
Disciplines:Classical mechanics