Technologies developed at PSU’s Center for Innovative Materials Processing through Direct Digital Deposition (CIMP- 3D) that enabled mapping of sensor data to X-Y-Z position during the deposition were integrated into commercial DED-AM systems. This involved transitioning both hardware modifications and custom software code to the AM Equipment Suppliers on the team.
Process map techniques originally developed at CMU were extended across a broader range of operating space. These process maps link power, velocity, and melt pool characteristics to prior grain structure during Ti-6Al-4V depositions. To capture results at both the low and high end of the energy spectrum, experiments were conducted on both the Optomec Laser Engineered Net Shaping (LENS) system at CIMP-3D and on Sciaky’s Electron Beam DM system. The results of this study were used to fashion and demonstrate a real-time microstructure controller.