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In this study, we leverage the massive amount of multi-modal on-machine metrology data generated from Laser Powder Directed Energy Deposition (LP-DED) to construct a comprehensive surrogate model of the 3D printing process. By employing…
Directed energy deposition (DED) is a promising metal additive manufacturing technology capable of 3D printing metal parts with complex geometries at lower cost compared to traditional manufacturing. The technology is most effective when…
Directed energy deposition (DED), a metal additive manufacturing process, is highly susceptible to process-induced defects such as geometric deviations, lack of fusion, and poor surface finish. This work presents a build-height-synchronized…
In additive manufacturing (AM), particularly for laser-based metal AM, process optimization is crucial to the quality of products and the efficiency of production. The identification of optimal process parameters out of a vast parameter…
Laser-directed-energy deposition (DED) offers advantages in additive manufacturing (AM) for creating intricate geometries and material grading. Yet, challenges like material inconsistency and part variability remain, mainly due to its…
An open source two-dimensional (2D) thermal finite element (FE) model of the Directed Energy Deposition (DED) process is developed using the Python-based FEniCS framework. The model incrementally deposits material ahead of the laser focus…
Directed Energy Deposition (DED) is a metal additive manufacturing process capable of building and repairing large, complex metal parts from a wide range of alloys. Its flexibility makes it attractive for multiple industrial applications,…
Directed Energy Deposition (DED) offers significant potential for manufacturing complex and multi-material parts. However, internal defects such as porosity and cracks can compromise mechanical properties and overall performance. This study…
Twin-wire laser directed energy deposition (TW-LDED) provides a promising route for alloying and fabrication of compositionally graded structures. However, inherent multiparameter coupling in twin-wire systems critically exacerbates both…
The mechanical performance of Directed Energy Deposition Additive Manufactured (DED-AM) components can be highly material dependent. Through in situ and operando synchrotron X-ray imaging we capture the underlying phenomena controlling…
Fabrication of nickel-titanium shape memory alloy through additive manufacturing has attracted increasing interest due to its advantages of flexible manufacturing capability, low-cost customization, and minimal defects. The process…
Laser beam welding is a non-contact joining technique that has gained significant importance in the course of the increasing degree of automation in industrial manufacturing. This process has established itself as a suitable joining tool…
Robotics Wire Arc Additive Manufacturing (WAAM) is governed by complex and nonlinear process dynamics coupling thermal field to the build geometry. The process may be regarded as a multi-input/multi-output dynamical system with welding…
Thermal multi-phase flow simulations are indispensable to understanding the multi-scale and multi-physics phenomena in metal additive manufacturing (AM) processes, yet accurate and robust predictions remain challenging. This book chapter…
Additive manufacturing (AM) is an emerging digital manufacturing technology to produce complex and freeform objects through a layer-wise deposition. High deposition rate robotic AM (HDRRAM) processes, such as cold spray additive…
Laser metal deposition (LMD) is an additive manufacturing technique, whose performances can be influenced by several factors and parameters. Monitoring their evolution allows for a better comprehension and control of the process, hence…
The advancement of machine learning promises the ability to accelerate the adoption of new processes and property designs for metal additive manufacturing. The molten pool geometry and molten pool temperature are the significant indicators…
Wire-feed laser additive manufacturing (WLAM) is gaining wide interest due to its high level of automation, high deposition rates, and good quality of printed parts. In-process monitoring and feedback controls that would reduce the…
Industry 4.0 has revolutionized manufacturing by driving digitalization and shifting the paradigm toward additive manufacturing (AM). Fused Deposition Modeling (FDM), a key AM technology, enables the creation of highly customized,…
Directed Energy Deposition (DED) processes offer one of the most versatile current techniques to additively manufacture and repair metallic components that have generatively designed complex geometries, and with compositional control. When…