SATPC0038089 Tab 04 4 SOW.pdf

Data-Enabled AM Qualification: Landscape Analysis on Integrating In-Situ Process Monitoring/Control in AM Qualification

Data-Enabled AM Qualification: Landscape Analysis on Integrating In-Situ Process Monitoring/Control in Additive Manufacturing Qualification

BACKGROUND

As the field of additive manufacturing (AM) quickly evolves, in-process control and in-situ monitoring (ISM) become more essential. This is due not only to the fact that quality of parts fabricated via AM directly relates to the control of process variables, but also because in-process control and ISM can capture the effect of various elements of the AM value chain, including powder and design processing and generate signals indicating process and ultimately part quality. ISM data can be used to gain a deeper understanding of underlying physics in AM, further optimize the process, and ultimately facilitate and expedite the process qualification. Despite all these benefits, the AM industry is yet to fully unlock advantages of ISM. The roadmap released by America Makes & ANSI Additive Manufacturing Standardization Collaborative (AMSC-v3) in 2023 identified multiple technical gaps related to in-process control and in-situ monitoring (e.g., gap PC3, PC12, PC16, and DA3) that require further research as a prerequisite to standard development. In 2022, the ASTM AM Center of Excellence (CoE), with support from NASA, held a workshop on ISM technology readiness in AM. The event brought together over 70 experts from the AM industry to discuss the latest developments. The workshop resulted in the publication of the “Strategic Guide: Additive Manufacturing In-Situ Monitoring Technology Readiness”, which was made available to the public and has since been referenced in several AM roadmapping efforts. This report provides an overview of the status of the ISM technology, and a list of high-priority research and standardization gaps that have to be addressed for enabling the use of ISM for qualification and certification purposes (Figure 1).

Data-Enabled AM Qualification: Landscape Analysis on Integrating In-Situ Process Monitoring/Control in AM

Figure 1. List of gaps and development opportunities for the use of ISM in AM (Source: Strategic Guide: Additive Manufacturing In-Situ Monitoring Technology Readiness – ASTM AM CoE)

The AM community recognizes that more integrated efforts are required to accelerate the pace of implementation and industrialization of ISM in advancing AM. This proposal provides a high-level framework for conducting such an integrated effort, which has been developed in close coordination with experts from NASA, AFRL, and FAA, and a support group consisting of Raytheon Technologies, Boeing, and Lockheed Martin, representing the AM end-user community.

OBJECTIVES

This effort aims to accomplish the following goals:

- Develop and disseminate an updated understanding of the current state of the ISM technology built upon the previous effort conducted in 2022

- Provide high priority (high impact and high feasibility) research needs and standardization gaps

SCOPE OF WORK

Data-Enabled AM Qualification: Landscape Analysis on Integrating In-Situ Process Monitoring/Control in AM the following tasks will be implemented:

Task 1: Landscape Analysis A landscape analysis of ISM in AM will be conducted, with a focus on process and part qualification. This task will be designed in three steps, including a literature review, experts' interviews, and an open-to public online survey. This task will aim to provide insight on how industry experts think of ISM as a tool for AM process qualification, its current and future use cases, and more importantly gaps that are hindering further utilization of ISM. Results of Task 1 will inform Task 2, by identifying topics that require further exploration and consensus building among stakeholders and industry experts.

Task 2: Reporting Findings will be consolidated of the landscape analysis in the form of a report, which can be used as a strategic guide for the use of ISM for AM process qualification. Figure 2 illustrates an example of distillation and consolidation of data from a range of sources into a strategic guide.

Figure 2. An example of distillation and consolidation of data into a strategic report (Source: Strategic Guide:

Additive Manufacturing In-Situ Monitoring Technology Readiness – ASTM AM CoE)

Note: The findings of this study can support the development of an in-person workshop to gather further input from AM stakeholders and develop a revised list of applied technologies relevant to AM ISM. The workshop will also help identify immediate or short- to mid-term approaches that facilitate the use of ISM for AM qualification.

SCHEDULE AND DELIVERABLES

Deliverables and completion dates for various tasks are listed in table below. The timeline assumes a project start date of no later than Apr. 15, 2025, and a completion date of no later than July 16, 2025.

Task # Description Deliverable Due Date

1 Landscape Analysis Raw data (literature review & Interviews) June 16, 2025

2 Reporting Strategic Report/Roadmap July 16, 2025