Metal Additive Manufacturing processes such as Directed Energy Deposition (DED) provide a scalable method to produce complex geometries with incredible benefits for applications, but there are challenges between concept design and producing a part, particularly as the size and throughput increases. In order to create high-quality, repeatable parts, in-process monitoring can be utilized to control the build process, collect data, and analyze the build data for quality control and certification. With Directed Energy Deposition, various monitoring and control modes are available to reduce parameter development times, improve build quality, and limit operator input during a build.
These control modes include melt pool, powder flow, laser power, and geometric monitoring and control. These control modes can be coupled with other parameter data and machine data in order to ensure the quality of the component and assist with certification efforts. A novel approach to certification utilizing digital build data, analysis, and correlation to material properties will be presented.
- Describe the benefits and challenges of production with Directed Energy Deposition (DED).
- Define a proposed process for digital build
- Conduct a further analysis of combining traditional certification with the proposed digital certification to create end use parts.