19100863DS01S
The research objective of this project is to demonstrate a prototype of a feedforward control (FFC) system for the laser powder bed process to produce higher quality additively manufactured (AM) builds. The FFC will compensate for the systemic variability arising from the statistics of the additive layer, powder bed, and the thermal phenomena. The compensation will be performed in nearâ real time on a full set of laser processing parameters. The FFC demonstration will utilize the ProX DMP laser powder bed system. Task 3: Purchase FFC hardware and assemble prototype design. Provide technical support for the design of the Top Plate for the ProX DMP320. AO will fabricate the Top Plate. 3D Systems and Penn State will install the top plate. 3D Systems provide technical support to Penn State for the assembly of the prototype FFC hardware. 13 Task 4: Implement capability to modify scan path and parameters on a layerâ byâ layer basis. 3D Systems will upgrade its system hardware to allow the layerâ byâ layer (Lâ L) modification of the build plan as needed by the FFC to control the layer and recoat variability. The deliverable will be a technical report / presentation of the firmware upgrade procedure, interface control document (ICD), a user manual for the execution of the multiâ dimensional control actions, and the verification tests that need to be performed in order to confirm the functionality and consistency of the upgraded firmware to enable very fine control of laser vectors and variation of the build plan on a Lâ L basis.
3D Systems, Inc.
Definitive Contract N6833519C0366
$108.7k 1/2/20 1910086PSU01S
The research objective of the proposed work is to demonstrate a prototype of a feedforward control (FFC) system for the laser powder bed (PBF) process to produce higher quality additively manufactured (AM) builds. The FFC will compensate for the systemic variability arising from the statistics of the additive layer, powder bed, and the thermal phenomena. The compensation will be performed in nearreal time on a full set of laser processing parameters. The FFC demonstration will utilize the ProX DMP PBF system. The Applied Research Laboratory at Penn State (ARL Penn State) will assist Applied Optimization (AO) and 3D Systems (3DS) in integrating Infrared (IR) and visible light (VIS) sensors onto a PBF machine, in implementing FFC strategies in real and near-real time, and by coordinating and conducting PBF experiments to produce test articles. Task 1) Select a notional Navy component and define its acceptance test requirements ARL Penn State will advise and participate in discussion with AO on a selected Navy component Task 2) Assess feasibility to simultaneously measure temperature at and ahead of the melt pool The objective of this task is to enable higher fidelity in the track-by-track (T-T) and point-by-point (P-P) FFC using simultaneous measurement of temperatures for the powder bed just ahead of the melt pool and the temperature of the molten material itself. ARL Penn State will evaluate options to measure the temperature ahead of the melt pool using co-axial sensors. At the completion of this task, ARL Penn State will provide a technical report / presentation on the feasibility of using a co-axial sensor to measure the temperature ahead and at the melt pool and an estimated cost of implementation. Task 3) Purchase FFC hardware and assemble prototype design ARL Penn State will work with 3DS to provide technical support to AO for the sizing and location of viewports and modifications to the top plate of the ProX DMP PBFsystem. These modifications will support the sensing for implementation of the FFC sensor suite. ARL Penn State will assist 3DS in installation of the top plate and verify the functionality of the top plate and attached sensors. ARL Penn State will install and implement a suite of sensors supporting optical hardware onto the ProX DMP 320. Sensors will include a currently available DSLR camera and a MWIR imager, as required. ARL Penn State will calibrate existing and new sensors. ARL Penn State will test the ability of data acquisition and control systems to receive and transmit signals to start/ end the operation of various sensors (VIS video camera, SWIR pyrometer and 3D laser scanner) as well as to coordinate FFC actions with the AO control software/ hardware. At the completion of the task, ARL Penn State will deliver a technical report/ presentation on: (1) The 12 installation of the new Top Plate and the verification of its functionality; (2) The integration of the sensor suite and its supporting hardware, verification data for sensor calibration, and its ability to coordinate with the layer-by-layer (L-L), T-T and P-P actions. Task 4) Implement capability to modify scan path and parameters on a layer-by-layer basis ARL Penn State will test the capability of 3DS-develped software/hardware to control laser vectors on a layer-by-layer basis. At the completion of the task, ARL Penn State will deliver a technical report/ presentation documenting testing and verification of the ability of the 3DS software/hardware to perform very fine control of laser vectors and build plan on a L-L basis. Task 5) Implement FFC algorithms for layer, powder, and thermal variability ARL Penn State will communicate L-L FFC actions to the upgraded firmware of the ProX DMP 320 in order to emulate the very fine control of laser vectors and build plan on a L-L basis. ARL Penn State will also implement the T-T and P-P strategies FFC strategies using their DAQ and control systems. At the completion of the task, ARL Penn State will deliver a technical report/ presentation on the communication of the L-L FFC algorithm output to the upgraded firmware, and on the implementation of the T-T and P-P FFC algorithms. Task 6) Integrate FFC for layer, powder, and thermal variability on commercial AM equipment ARL Penn State will coordinate up to two additive manufacturing builds with 3DS for production of test articles and to test the integration of the L-L, T-T and P-P FFC algorithms. Where possible, enhancement to sensing and control systems will be made. ARL Penn State will perform limited metallography in order to support the evaluation of build quality improvement using FFC. At the completion of the task, ARL Penn State will deliver a technical report/ presentation on (1) integration of the sensor suite and its supporting hardware, sensor calibration, the L-L, T-T and P-P FFC procedures; (2) Sensor data collected during the deposition trials, the results of the deposition trial and the metallography. Task 7) Demonstrate improved build quality for the notional AM component ARL Penn State will coordinate up to six AM builds for production of test articles with 3DS and execute the FFC algorithms along with support from the full suite of sensors. One or more of these builds will be produced using virgin powder. ARL Penn State will perform limited metallography in order to support the evaluation of build quality improvement using FFC. At the end of the task, ARL Penn State will deliver a technical report/ presentation on (1) the use of the integrated sensor suite and the FFC procedures to produce the test articles and a Navy component; (2) Sensor data, metallography data, and the results of the deposition trial; (3) Assessment of build quality improvement with the use of FFC. Phase II Deliverables Progress reports will be provided on a quarterly (every 3 months) basis. Monthly budgetary reports will be provided. A final technical report will be provided before the program end date. Reports required at the end of each task may be incorporated into the quarterly progress report or the final technical report.
The Pennsylvania State University
Definitive Contract N6833519C0366
$182.0k 12/16/19