Development of In-Process Monitoring Closed-Loop Feedback for Use in Aluminum Alloy Additive Manufacturing (AM) Applications

Development of In-Process Monitoring Closed-Loop Feedback for Use in Aluminum Alloy Additive Manufacturing (AM) Applications

Award Information
Agency: Department of Defense
Branch: Army
Contract: W911W6-18-C-0006
Agency Tracking Number: A171-003-1417
Amount: $149,819.61
Phase: Phase I
Program: SBIR
Awards Year: 2018
Solicitation Year: 2017
Solicitation Topic Code: A17-003
Solicitation Number: 2017.1
Small Business Information
850 Energy Drive, Idaho Falls, ID, 83401
DUNS: 089822014
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Dr. Xiawa Wu
 (716) 621-8337
 ewu@sentientscience.com
Business Contact
 Jason Rios
Phone: (716) 328-3422
Email: jrios@sentientscience.com
Research Institution
N/A
Abstract
Sentient Corporation proposes to integrate its DigitalClone Component (DCC) physics-based modeling technology and Johns Hopkins University Applied Physics Laboratorys in-situ thermal sensors to develop a comprehensive sensor-based tool to monitor, identify and locate defects in metallic additive manufacturing, and create a DCC model-enabled feedback loop to correct the process-induced defects to improve part quality. In Phase I, Sentient will demonstrate that an in-process sensor measured thermograph can be successfully linked to different types of defects on the build surface, and Sentients DCC model can be used to optimize the process parameters and correct known defects. The corrected part will be experimentally tested to show improved material properties and reduced residual stress in Phase I option. In Phase II, Sentient will partner with Sikorsky to further develop this flaw detection-correction technology into a closed-loop application in an AM process, and select suitable components in Army helicopter gearbox to demonstrate the developed application. It is expected that at the end of Phase II, the developed technique will meet the goal of this solicitation with an in-process method that can improve the repeatability of the material properties, geometry and quality of AM manufactured aluminum parts.

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

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