ENHANCING PART QUALITY MANAGEMENT USING AN HOLISTIC DATA FUSION FRAMEWORK IN METAL POWDER BED FUSION ADDITIVE MANUFACTURING

Published

March 5, 2024

Author(s)

Zhuo Yang, Jaehyuk Kim, Yan Lu, Albert T. Jones, Paul Witherell, Ho Yeung, Hyunwoong Yang

Abstract

Metal powder bed fusion-based additive manufacturing (AM) processes have gained widespread adoption for producing complex parts with high performance. However, a multitude of factors still affect the build process, which leads to great challenges in achieving consistent and reliable part quality. To address this challenge, simulations and measurements have been progressively deployed to provide valuable insights into the quality of individual builds. This paper proposes an AM, data-fusion framework that combines data sources beyond a single-part development cycle. Those sources include the aggregation of measurements from multiple builds and the outputs from models and simulations. Both can be used to support decision makings that can improve part quality. The effectiveness of the holistic AM data fusion framework is illustrated through three use case scenarios: one that fuses process data from a single build, one that fusses data from a build and simulation, and one that fuses data from multiple builds. The case studies demonstrate that a data fusion framework can be applied to effectively detect over-melting scan strategies, monitor material melting conditions, and predict down-skin surface defects. Overall, the proposed method provides a practical solution for enhancing part quality management when individual data sources or models have intrinsic limitations.

Citation

ASME Journal of Computing and Information Science in Engineering

Pub Type

Journals

Download Paper

https://doi.org/10.1115/1.4064528

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Keywords

additive manufacturing, process planning, data fusion, predictive modeling

Citation

Yang, Z. , Kim, J. , Lu, Y. , Jones, A. , Witherell, P. , Yeung, H. and Yang, H. (2024), ENHANCING PART QUALITY MANAGEMENT USING AN HOLISTIC DATA FUSION FRAMEWORK IN METAL POWDER BED FUSION ADDITIVE MANUFACTURING, ASME Journal of Computing and Information Science in Engineering, [online], https://doi.org/10.1115/1.4064528, https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=936832 (Accessed April 27, 2024)