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: W911W6-19-C-0006
Agency Tracking Number: A2-7455
Amount: $560,069.13
Phase: Phase II
Program: SBIR
Solicitation Topic Code: A17-003
Solicitation Number: 2017.1
Timeline
Solicitation Year: 2017
Award Year: 2019
Award Start Date (Proposal Award Date): 2019-05-14
Award End Date (Contract End Date): 2020-05-13
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
 Jingfu Liu
 (832) 260-5660
 jliu@sentientscience.com
Business Contact
 Melissa McReynolds
Phone: (716) 239-8215
Email: mmcreynolds@sentientscience.com
Research Institution
N/A
Abstract
The overall goal of this project is to develop an in-process defect monitoring and correction technique for additive manufacturing (AM) of aluminum alloy to improve repeatability for geometric dimensions, material properties, and quality. In Phase I, Sentient collaborated with Johns Hopkins University Applied Physics Lab, and successfully completed all proposed tasks demonstrating two key capabilities: 1) in-situ defect monitoring capability using an infrared (IR) camera, and 2) defect correction capability using optimized AM process parameters through advanced modeling and simulation. The goal of Phase II is to develop the prototype of in-process defect monitoring and correction close-loop feedback system to optimize AM process for flaw control and defect correction. The in-situ defect monitoring capability and advanced simulation capability demonstrated in Phase I will be integrated in Matsuura LUMEX series powder bed fusion platform to demonstrate real-time close-loop feedback control capability. A comprehensive testing (e.g. microstructure, yield strength, fatigue life) will be performed on coupons made by the new AM system to demonstrate the improved part quality compared to baseline properties of as-build AM parts or conventionally sand casted parts. Finally, AM components (i.e. full-size gearbox) will be fabricated using prototype of the new AM system.

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

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