Control of directed energy deposition process for manufacturing complex geometry components by Additive Manufacturing (AM)

• Grant number: 19/00343-1
• Support Opportunities: Scholarships in Brazil - Doctorate
• Start date: April 01, 2019
• End date: February 28, 2023
• Field of knowledge: Engineering - Mechanical Engineering - Manufacturing Processes
• Principal Investigator: Reginaldo Teixeira Coelho
• Grantee: Kandice Suane Barros Ribeiro
• Host Institution: Escola de Engenharia de São Carlos (EESC). Universidade de São Paulo (USP). São Carlos , SP, Brazil
• Associated research grant: 16/11309-0 - The study, development and application of a hybrid process: Additive Manufacturing (AM) plus High Speed Machining/Grinding (HSM/G), AP.TEM

Abstract

Additive Manufacturing (AM) has been an area of great interest for both universities and industries due to its new product properties and sustainable production capabilities. One of AM main process for manufacturing metal parts is the Directed Energy Deposition (DED), which is based on a simultaneous deposition of metal powder and laser beam layer by layer through a pre-defined deposition toolpath generated in CAM software. This process is commonly applied in repair and rebuild of damaged and worn components, and to manufacture new parts in hard-to-machine materials. However, during fabrication the complex thermal activity of newly deposited layers and its influence in previous deposited material affects the quality of metal deposition, making the reprodudibility of parts and maintenance of microstructure and mechanical properties a challenge for production. With this regard, the aim of this research is to develop a method for controlling DED processes parameters e.g. deposited layer thickness, feedstock and energy delivered to accomplish effective material joining and reprodudibility of additive manufactured parts. A compound of different optical methods of monitoring laser processes has been applied in the literature but acoustic and optical methods are rarely combined. For quality and process reliability purposes, such solution might produce interesting data towards closed loop manufacturing control and further knowledge in AM via DED. (AU)

Scientific publications

(10)

(References retrieved automatically from Web of Science and SciELO through information on FAPESP grants and their corresponding numbers as mentioned in the publications by the authors)

MARIANI, FABIO EDSON; RIBEIRO, KANDICE SUANE BARROS; LOMBARDI, AMADEU NETO; CASTELETTI, LUIZ CARLOS; COELHO, REGINALDO TEIXEIRA. Effect of Laser Polishing Post-Processing Technique on the Roughness and Wear Resistance of Inconel 625 Deposited by Laser Cladding on AISI 304L Stainless Steel. Journal of Materials Engineering and Performance, JUN 2021. (19/00343-1, 16/11309-0, 19/26362-2)

MARIANI, FABIO EDSON; RIBEIRO, KANDICE SUANE BARROS; LOMBARDI, AMADEU NETO; CASTELETTI, LUIZ CARLOS; COELHO, REGINALDO TEIXEIRA. Effect of Laser Polishing Post-Processing Technique on the Roughness and Wear Resistance of Inconel 625 Deposited by Laser Cladding on AISI 304L Stainless Steel. Journal of Materials Engineering and Performance, v. 30, n. 9, SI, p. 6713-6721, SEP 2021. (19/00343-1, 19/26362-2, 16/11309-0)

GOMES, MILLA CAROLINE; DOS SANTOS, ALINE GONCALVES; DE OLIVEIRA, DEBORAH; FIGUEIREDO, GABRIEL VIANA; BARROS RIBEIRO, KANDICE SUANE; BARRAGAN DE LOS RIOS, GERMAN ALBERTO; DA SILVA, MARCIO BACCI; COELHO, REGINALDO TEIXEIRA; HUNG, WAYNE N. P.. Micro-machining of additively manufactured metals: a review. INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, v. 118, n. 7-8, SEP 2021. (20/03110-5, 19/00343-1, 19/08926-6, 16/11309-0)

RIBEIRO, KANDICE S. B.; NUNEZ, HENRIQUE H. L.; VENTER, GIULIANA S.; DOUDE, HALEY R.; COELHO, REGINALDO T.. A hybrid machine learning model for in-process estimation of printing distance in laser Directed Energy Deposition. INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, v. 127, n. 7-8, p. 12-pg., 2023-06-10. (16/11309-0, 20/03119-2, 19/00343-1)

DE OLIVEIRA, DEBORAH; GOMES, MILLA CAROLINE; DOS SANTOS, ALINE GONCALVES; BARROS RIBEIRO, KANDICE SUANE; VASQUES, IAGO JOSE; COELHO, REGINALDO TEIXEIRA; DA SILVA, MARCIO BACCI; HUNG, NGUYEN WAYNE. Abrasive and non-conventional post-processing techniques to improve surface finish of additively manufactured metals: a review. PROGRESS IN ADDITIVE MANUFACTURING, v. N/A, p. 18-pg., 2022-07-21. (19/08926-6, 19/00343-1, 16/11309-0, 20/03110-5)

RIBEIRO, KANDICE S. B.; MARIANI, FABIO E.; IDOGAVA, HENRIQUE T.; DA SILVA, GUSTAVO C.; SILVEIRA, ZILDA C.; DE LIMA, MILTON S. F.; COELHO, REGINALDO T.; FRATINI, L; RAGAI, I. Evaluation of laser polishing as post-processing of Inconel 625 produced by Directed Energy Deposition. 49TH SME NORTH AMERICAN MANUFACTURING RESEARCH CONFERENCE (NAMRC 49, 2021), v. 53, p. 7-pg., 2021-01-01. (19/26362-2, 16/11309-0, 19/00343-1)

RIBEIRO, KANDICE S. B.; NUNEZ, HENRIQUE H. L.; JONES, JASON B.; COATES, PETER; COELHO, REGINALDO T.; FRATINI, L; RAGAI, I. A novel melt pool mapping technique towards the online monitoring of Directed Energy Deposition operations. 49TH SME NORTH AMERICAN MANUFACTURING RESEARCH CONFERENCE (NAMRC 49, 2021), v. 53, p. 9-pg., 2021-01-01. (16/11309-0, 19/00343-1, 20/03119-2)

RIBEIRO, KANDICE S. B.; MARIANI, FABIO E.; COELHO, REGINALDO T.; FRATINI, L; RAGAI, I; WANG, L. A Study of Different Deposition Strategies in Direct Energy Deposition (DED) Processes. 49TH SME NORTH AMERICAN MANUFACTURING RESEARCH CONFERENCE (NAMRC 49, 2021), v. 48, p. 8-pg., 2020-01-01. (19/00343-1)

MOREIRA, ALCINDO F.; RIBEIRO, KANDICE S. B.; MARIANI, FABIO E.; COELHO, REGINALDO T.; FRATINI, L; RAGAI, I; WANG, L. An Initial Investigation of Tungsten Inert Gas (TIG) Torch as Heat Source for Additive Manufacturing (AM) Process. 49TH SME NORTH AMERICAN MANUFACTURING RESEARCH CONFERENCE (NAMRC 49, 2021), v. 48, p. 7-pg., 2020-01-01. (19/00343-1)

SESTITO, GUILHERME SERPA; VENTER, GIULIANA SARDI; BARROS RIBEIRO, KANDICE SUANE; RODRIGUES, ALESSANDRO ROGER; DA SILVA, MAIRA MARTINS. In-process chatter detection in micro-milling using acoustic emission via machine learning classifiers. INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, v. 120, n. 11-12, p. 11-pg., 2022-04-25. (19/00343-1)

Academic Publications

(References retrieved automatically from State of São Paulo Research Institutions)

RIBEIRO, Kandice Suane Barros. An innovative monitoring method using a software capable of 3D mapping data from laser Directed Energy Deposition (L-DED) process. 2023. Doctoral Thesis - Universidade de São Paulo (USP). Escola de Engenharia de São Carlos (EESC/SBD) São Carlos.