Browsing by Subject "Oak Ridge National Laboratory"

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Melt Pool Monitoring for Control and Data Analytics in Large-Scale Metal Additive Manufacturing
(University of Texas at Austin, 2019) Gibson, B.T.; Bandari, Y.K.; Richardson, B.S.; Roschli, A.C.; Post, B.K.; Borish, M.C.; Thornton, A.; Henry, W.C.; Lamsey, M.; Love, L.J.
Laser-wire based Directed Energy Deposition (DED) processes are being developed at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility, in collaboration with GKN Aerospace, for large volume metal additive manufacturing of metallic structures. The technology has the potential to deliver reduced costs and lead times when compared to conventional methods of manufacturing in several industries. While complex structures are being produced with relatively high deposition rates and at near-net shape, issues persist with achieving consistent geometric accuracy and thermal stability. A significant research effort is focused on developing coordinated, multi-modal sensing and control for addressing these issues. An introduction to this large-volume metal process will be provided, followed by investigations into real-time thermal monitoring capabilities that support control and data analytics frameworks. Studies focused on melt pool monitoring via infrared thermography, thermal and geometric effects on melt pool size measurement, and interactions between process variables and thermal monitoring metrics are presented.
Multi-Material Process Planning for Additive Manufacturing
(University of Texas at Austin, 2019) Patrick, Steven; Nycz, Andrzej; Noakes, Mark
A key process in additive manufacturing is converting a 3D model into a set of instructions that a robot can parse and implement. This process is commonly referred to as slicing. Oak Ridge National Laboratory’s (ORNL) Metal Big Area Additive Manufacturing (MBAAM) team at the Manufacturing Demonstration Facility (MDF) has developed a slicing software that generates instructions for multiple materials within the same part. The benefits of using multiple materials are lower cost, fewer voids, and greater control over the print. However, a significant challenge arose when the two different materials had different layer heights and bead widths. A layer of complexity was added not only when the material changed from layer to layer, but also when different materials were used within a single layer. These challenges were addressed by assigning bead types and profile types to printing regions and layers, respectively.
Review of Current Problems and Developments in Large Area Additive Manufacturing (LAAM)
(University of Texas at Austin, 2021) Crisp, Tyler G.; Weaver, Jason M.
Large Area Additive Manufacturing (LAAM), also known as Big Area Additive Manufacturing (BAAM), is a screw extrusion, pellet-fed additive manufacturing technology. The large build area, rapid build speed, and inexpensive pelletized feedstock of LAAM are major advantages over conventional AM methods. LAAM has a large variety of applications in areas including energy, automotive, aerospace, high volume production, and composite molds. However, LAAM is not without its challenges. The largest challenges LAAM faces include mechanical properties, uniformity and precision, and predictability of composite material properties. The goal of this paper is to present current research regarding challenges in LAAM, methods of addressing those challenges, developments, and applications, as well to highlight further research to be done.
SkyBAAM Large-Scale Fieldable Deposition Platform System Architecture
(University of Texas at Austin, 2019) Chesser, Phillip; Post, Brian; Lind, Randy; Roschli, Alex; Atkins, Celeste; Boulger, Alex; Mhatre, Paritosh; Lloyd, Pete
Oak Ridge National Laboratory (ORNL) is currently developing a concrete deposition system for infrastructure-scale printed objects. This system, called SkyBAAM, uses a cable driven motion platform to manipulate the print head. This work focuses on the general aspects of the system architecture, including arrangement of the cable driven platform, general high-level control methodology, and system accuracy, along with concrete deposition methods. Results and demonstration prints will be shown.
Wire Co-Extrusion with Big Area Additive Manufacturing
(University of Texas at Austin, 2019) Atkins, Celeste; Heineman, Jesse; Chesser, Phillip; Roschli, Alex; Post, Brian; Lloyd, Peter; Love, Lonnie; Lind, Randall
Oak Ridge National Laboratory’s Manufacturing Demonstration Facility is developing a system that will deposit and embed conductive and resistive elements within a printed bead of material. The system was implemented on a Big Area Additive Manufacturing (BAAM) system using a co-extruding nozzle. It has already been demonstrated that BAAM is useful for the tooling industry, but this could be a great improvement on an established application of BAAM parts. This system will provide the ability to control and monitor the surface of additively manufactured (AM) parts. It will also enable self-heating surfaces of AM parts, which is particularly useful in tooling applications. This system could even be used in the future for embedding other materials not found in pellet form in BAAM parts. This work will cover the development of the co-extrusion system and its integration with the dual-port nozzle and the BAAM system.
Wire-Arc Additive Manufacturing: Invar Deposition Characterization
(University of Texas at Austin, 2019) Fowler, J.; Nycz, A.; Noakes, M.; Masuo, C.; Vaughan, D.
This paper explains and analyzes an investigation into the characteristics of Invar, a Nickel-Iron alloy, with regards to deposition through Wire-Arc Additive Manufacturing performed by the Metal Big Area Additive Manufacturing (MBAAM) team at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility (MDF). The Invar alloy is extremely valuable to multiple fields because of its thermal expansion properties. These fields will attain financial benefits when turning to additive manufacturing as the future production technique for their Invar parts. As such, it will be necessary for AM research to become accustomed with the characteristics of Invar deposition. One of the potential AM techniques that has the potential to carry out printing with this material is Wire-Arc AM. The goal of this paper is to narrow down and call out different welding parameters that optimize the characteristics of Invar deposition using the Wire-Arc AM technique.