The Penn State Research Foundation

Other

Rolls-Royce Corporation

Arizona State University

Abdalla R Nassar

Edward W Reutzel

Alexander J Dunbar

Scott Nelson

Owen Hildreth

John Grubbs

Baily Thomas

Wesam Abdalla Nassar

Robert W Smith

Timothy W Simpson

Tim Simpson

Christopher Lefky

David Wright

M Hatem Abdalla Nassar

Jacob P Morgan

Evan P Diewald

Zackary Keller Snow

David J Corbin

Jan Petrich

Jason Scherer

M Hatem Nassar

Embodiments relate to in-situ process monitoring of a part being made via additive manufacturing. The process can involve capturing computed tomography (CT) scans of a post-built part. A neural network (NN) can be used during the build of a new part to process multi-modal sensor data. Spatial and temporal registration techniques can be used to align the data to x,y,z coordinates on the build plate. During the build of the part, the multi-modal sensor data can be superimposed on the build plate. Machine learning can be used to train the NN to correlate the sensor data to a defect label or a non-defect label by looking to certain patterns in the sensor data at the x,y,z location to identify a defect in the CT scan at x,y,z. The NN can then be used to predict where defects are or will occur during an actual build of a part.

In-situ process monitoring for powder bed fusion additive manufacturing (PBF AM) processes using multi-modal sensor fusion machine learning

An additive manufacturing system may include an energy delivery device configured to deliver energy to a component to form a melt pool at least partially surrounded by a cooling region; and an optical system comprising: an imaging device; and an occulting device, wherein the occulting device is configured to occult at least part of thermal emissions produced by the energy and the melt pool and transmit at least some thermal emissions produced by the cooling region.

Occulting device for optical system in additive manufacturing systems

A powder flow monitoring system may include a computing device configured to receive image data representing illuminated powder of a powder stream between a powder delivery device and a build surface of a component, generate a representation of the powder stream based on the image data, and output the representation of the powder stream for display at a display device.

Powder flow measurement in additive manufacturing systems

Embodiments of the systems can be configured to receive electromagnetic emissions of a substrate (e.g., a build material of a part being made via additive manufacturing) by a detector (e.g., a multi-spectral sensor) and generate a ratio of the electromagnetic emissions to perform spectral analysis with a reduced dependence on location and orientation of a surface of the substrate relative to the multi-spectral sensor. The additive manufacturing process can involve use of a laser to generate a laser beam for fusion of the build material into the part. The system can be configured to set the multi-spectral sensor off-axis with respect to the laser (e.g., an optical path of the multi-spectral sensor is at an angle that is different than the angle of incidence of the laser beam). This can allow the multi-spectral sensor to collect spectral data simultaneously as the laser is used to build the part.

Multi-spectral method for detection of anomalies during powder bed fusion additive manufacturing

Methods and systems are described for fabricating a component using 3D printing. A 3D printed piece is created including a body of the component, a support structure, and a first sacrificial interface region coupling the body of the component to the support structure. The body of the component is formed of a first metal or ceramic material and the first sacrificial interface region is formed at least partially of a second metal or ceramic material. The body of the component is then separated from the support structure by applying a chemical or electrochemical dissolution process to the 3D printed piece. Because the second metal or ceramic material is less resistant to the dissolution process than the first metal or ceramic material, the first sacrificial interface region at least partially dissolves, thereby separating the body of the metal component from the support structure, without dissolving the body of the component.

Fabricating metal or ceramic components using 3D printing with dissolvable supports of a different material

Systems and methods are disclosed for fabricating a metal or ceramic component using a 3D printer. An entire 3D printed piece, including both the metal or ceramic component and one or more support structures, is created of a first metal or ceramic material. A sensitization layer is applied to all or part of the 3D printed piece to chemically alter portions of the first metal or ceramic material near the surface making those portions of the material more sensitive to the etching process. The etching process causes the affected material to deplete and separates the component from the support structures without requiring mechanical machining.

Dissolving metal supports in 3D printed metals and ceramics using sensitization

A method for manufacturing material voxel-by-voxel using directed-energy deposition is given. Using the method, unsupported structures, via voxel-wise directed-energy deposition, with steep overhangs is described and demonstrated. Methods for forming arbitrarily-complex structures and shaped voxels and surfaces are also given. A method for forming materials with internally-varying properties is also given. The method utilizes a pulsed or modulated, rather than continuous-wave energy source, thus allowing rapid solidification of voxels, rather than contours, hatches or tracks. Tuning of pulsing or modulation, material flow, and deposition-path parameters allows the buildup of unsupported material using standard directed-energy deposition processing heads and 3-axis stages, for example. The methods are demonstrated using a modified-directed-energy-deposition processes and is applicable to powder-bed for the buildup of three-dimensional components, repair and the addition of features to existing components.

Method for manufacturing overhanging material by pulsed, voxel-wise buildup

A method is described for making a frozen French fry-style food product, having from about 50.0% to about 70.0% moisture, from about 4.0% to about 8.0% protein, from about 2.5% to about 5.0% fat, and from about 0.25% to about 0.50% fibers, in addition to calcium and phosphorous sources. This frozen potato-based product is made from a composition comprising steam peeled and cooked whole raw potatoes, soaked or cooked whole beans processed and mixed with the peeled cooked potatoes to create a dough-like consistency to which proteinaceous flours, starchy flours, vegetable oil, and other additives are added and blended into a homogeneous potato-based dough. The homogeneous potato-based dough is extruded into a rope-like extrudate, which is partially steam-cooked and then immediately cooled. The cold rope-like extrudate is cut into uniform small rods, 2.5 inches long, which are packaged and stored under blast freezing conditions.

Method of making french fry-style potato products

A method is described for producing extruded French Fries-Style products from dough containing between 45% to 50% moisture, from 4% to 8% protein, and from 0.25% to 0.5% fibers. Said dough is composed of steam-peeled potatoes soaked beans, desired spices, flavors, colors, and fortified with vitamins and minerals. The dough is pumped under vacuum to specific forming heads containing openings of desired shapes and dimensions. The continuous extrudate coming from said forming heads is received over a solid conveying belt traveling inside a steam-heated path at an adjusted speed to expose the extrudate to steam for a certain length of time to bring the temperature of the center of the extrudate from 140 to 190 degrees Fahrenheit. The extrudate is then received over a belt-conveyer traveling inside a freezing-tunnel where it is exposed to blasts of cooled air for a period of time to lower the temperature of the extrudate to 45 and degrees Fahrenheit or lower. The extrudate is cut to desired length, then packaged and stored under blast freezing conditions.

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State College, PA, United States of America

Abdalla R Nassar