Innovative Additive Manufacturing Process for Successful Production of 7000 Series Aluminum Alloy Components Using Smart Optical Monitoring System

Choi, J.; Mazumder, Jyoti; Rice, A. J.

doi:10.4271/2020-01-1300

SAE Technical Paper Series 2020

DOI: 10.4271/2020-01-1300

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Innovative Additive Manufacturing Process for Successful Production of 7000 Series Aluminum Alloy Components Using Smart Optical Monitoring System

J. Choi¹,

Jyoti Mazumder

A. J. Rice³

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Cited by 2 publications

References 33 publications

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Cooling rate and dendrite spacing control in direct metal deposition printed Cu-Fe alloys

Sprague

Mazumder

Misra

2022

Journal of Laser Applications

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Over the last several decades, additive manufacturing (AM) has been primarily used for rapid prototyping or to create novel geometries that would be difficult or impossible to create by normal manufacturing methods. More recently, research has been focused on expanding the list of materials that can be made through additive manufacturing, opening a greater range of material properties for this manufacturing method. Due to the unusual conditions during AM, including the high cooling rates and voxel by voxel method of production, AM parts often have anisotropic material microstructures and properties. In this investigation, the laser power, composition, and nozzle head speed during direct metal deposition of copper-iron alloys was varied to understand how the grain structure within the printed parts could be changed and controlled. The resulting dendrite spacing was measured and compared to calculated cooling rates from Gaussian beams on flat plates under similar material and laser properties, which resulted in a cooling rate to dendrite spacing relationship following an inverse square root, as is found in other dendritic systems [Young and Kerkwood, Metall. Trans. A 6, 197–205 (1975)]. Thus, it is demonstrated that in the Cu-Fe system, dendrite spacing can be controlled through manipulation of printing parameters.

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Cooling rate and dendrite spacing control in direct metal deposition printed Cu-Fe alloys

Sprague

Mazumder

Misra

2022

Journal of Laser Applications

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Spectroscopy-based smart optical monitoring system in the applications of laser additive manufacturing

Choi¹,

Wooldridge

Mazumder

2023

Journal of Laser Applications

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The potential defects during the additive manufacturing (AM) process greatly deteriorate the mechanical properties of the fabricated structures and, as a result, increase the risks of part fatigue failure and even disasters. As laser additive manufacturing is such a complex process, many different physical phenomena such as electromagnetic radiation, optical and acoustic emission, and plasma generation will occur. Unlike vision and acoustic methods, the spectroscopy based smart optical monitoring system (SOMS) provides atomic level information revealing mechanical and chemical condition of the product. By monitoring plasma, multiple information such as line intensity, standard deviation, plasma temperature, or electron density, and by using different signal processing algorithms such as vector machine training or wavelet transforming, AM defects have been detected and classified. Utilizing two fiber optic components, a bifurcated fiber and a split fiber, the experimental results were performed to improve SOMS signal-to-noise ratio. Defects, including subsurface pores and sudden changes of process parameters including shielding gas shut-off and foreign substance, were identified by the spectroscopy based SOMS. For chemical composition characterization, a degree of dilution in terms of chemical element variation is identified by a spectral peak intensity ratio through the SOMS. It turned out that the information on the Cr/Fe ratio of deposit at a certain layer is vital to design the mechanical property in the IN625 deposition on the mild steel case. The SOMS has also demonstrated that the chemistry ratio can be determined from the calibration curve method based on the known alloy samples and that the ratio of the maximum intensities of multiple species provides more information about the quality of the alloy.

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Innovative Additive Manufacturing Process for Successful Production of 7000 Series Aluminum Alloy Components Using Smart Optical Monitoring System

Cited by 2 publications

References 33 publications

Cooling rate and dendrite spacing control in direct metal deposition printed Cu-Fe alloys

Cooling rate and dendrite spacing control in direct metal deposition printed Cu-Fe alloys

Spectroscopy-based smart optical monitoring system in the applications of laser additive manufacturing

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