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Defect Detection from In-situ Monitoring of LPBF Additive Manufacturing

Award Information
Agency: Department of Defense
Branch: Navy
Contract: N68335-23-C-0050
Agency Tracking Number: N222-117-0143
Amount: $139,967.00
Phase: Phase I
Program: SBIR
Solicitation Topic Code: N222-117
Solicitation Number: 22.2
Solicitation Year: 2022
Award Year: 2023
Award Start Date (Proposal Award Date): 2022-11-07
Award End Date (Contract End Date): 2023-05-09
Small Business Information
6820 Moquin Dr NW
Huntsville, AL 35806-2900
United States
DUNS: 185169620
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
Principal Investigator
 J. Vernon Cole
 (256) 726-4800
Business Contact
 Edward McAbee
Phone: (256) 361-0817
Research Institution

Additive Manufacturing provides many potential advantages, relative to traditional manufacturing methods, for the Navy and other organizations in the aerospace community.  Although flight critical aerospace quality metal alloy components have been produced and flight tested, confidently expanding the use of AM in these applications requiring stringent quality control and repeatability. The vendor and user community has been continually investigating multiple in-situ process sensor technologies to enable advancements in process monitoring and control. Machine Learning (ML) methods and systematic, intelligent fusion of sensor data provides an attractive route to more confidently warn the user of the presence, location, and type of defects in AM parts. In this Phase I effort, CFD Research and our partners from the Advanced Research Laboratory Penn State will implement state-of-the-art ML methods with data fusion strategies. ML training and application will demonstrate the feasibility of advancing defect detection and defect location prediction accuracy, and of predicting defect types, from multiple in-situ sensor modes. The selected ML model structures will enable efficient, intelligent identification of the most important sensor data for future model improvements. In Phase II, extensive testing and training will be used to validate the models and extend the methodology for estimation of critical mechanical properties.

* Information listed above is at the time of submission. *

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