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Early detection and correction of defects are critical in additive manufacturing (AM) to avoid build failures. In this paper, we present a multisensor fusion-based digital twin for in-situ quality monitoring and defect correction in a…
Architected materials produced by powder bed fusion metal additive manufacturing technique offer realization of complex structural hierarchies that mimic the principles of crystal plasticity while still being ultralight-weight, though…
Additive Manufacturing (AM) has enabled the fabrication of metallic cellular materials that are of interest in the design of lightweight impact resistant structures. However, there is a need to understand the interactions between: (i) the…
Reverse engineering can be used to derive a 3D model of an existing physical part when such a model is not readily available. For parts that will be fabricated with subtractive and formative manufacturing processes, existing reverse…
Multi-modality image fusion aims to combine different modalities to produce fused images that retain the complementary features of each modality, such as functional highlights and texture details. To leverage strong generative priors and…
Wire-feed laser additive manufacturing is an emerging fabrication technique capable of highly automated large-scale volume production that can reduce both material waste and overall cost while improving product lead times. Quality assurance…
The thermal and mechanical behaviors of powders are important for various additive manufacturing technologies. For powder bed fusion, capturing the temperature profile and the packing structure of the powders prior to melting is challenging…
In additive manufacturing, the optimal processing conditions need to be determined to fabricate porosity-free parts. For this purpose, the design space for an arbitrary alloy needs to be scoped and analyzed to identify the areas of defects…
Thermal fracture is prevalent in many engineering problems and is one of the most devastating defects in metal additive manufacturing. Due to the interactive underlying physics involved, the computational simulation of such a process is…
Additive manufacturing of metal parts involves phase transformations and high temperature gradients which lead to uneven thermal expansion and contraction, and, consequently, distortion of the fabricated components. The distortion has a…
Spreading uniform and dense layers is of paramount importance to creating high-quality components using powder bed additive manufacturing (AM). Blade-like tools are often employed for spreading powder metal feedstocks, especially in laser…
Design under uncertainty is a challenging problem, as a systems performance can be highly sensitive to variations in input parameters and model uncertainty. A conventional approach to addressing such problems is robust optimization, which…
Additive manufacturing, particularly fused deposition modeling, is transforming modern production by enabling rapid prototyping and complex part fabrication. However, its layer-by-layer process remains vulnerable to faults such as nozzle…
Material extrusion is one of the most commonly used approaches within the additive manufacturing processes available. Despite its popularity and related technical advancements, process reliability and quality assurance remain only partially…
The conflict between stiffness and toughness is a fundamental problem in engineering materials design. However, the systematic discovery of microstructured composites with optimal stiffness-toughness trade-offs has never been demonstrated,…
With the rapid development of Additive Manufacturing (AM) comes an urgent need for advanced monitoring and control of the process. Many aspects of the AM process play a significant role in the efficiency, accuracy and repeatability of the…
This work introduces an innovative parallel, fully-distributed finite element framework for growing geometries and its application to metal additive manufacturing. It is well-known that virtual part design and qualification in additive…
Mathematical models simulate various events under different conditions, enabling an early overview of the system to be implemented in practice, reducing the waste of resources and in less time. In project optimization, these models play a…
Automotive companies are increasingly looking for ways to make their products lighter, using novel materials and novel bonding processes to join these materials together. Finding the optimal process parameters for such adhesive bonding…
ANN (Artificial Neural Networks) modeling methodology was adopted for predicting mechanical properties of aluminum cast composite materials. For this purpose aluminum alloy were developed using conventional foundry method. The composite…