SBIR-STTR Award

Sentient Corporation proposes to integrate its DigitalClone Component (DCC) physics-based modeling technology and Johns Hopkins University Applied Physics Laboratorys in-situ thermal sensors to develop a comprehensive sensor-based tool to monitor, identify and locate defects in metallic additive manufacturing, and create a DCC model-enabled feedback loop to correct the process-induced defects to improve part quality. In Phase I, Sentient will demonstrate that an in-process sensor measured thermograph can be successfully linked to different types of defects on the build surface, and Sentients DCC model can be used to optimize the process parameters and correct known defects. The corrected part will be experimentally tested to show improved material properties and reduced residual stress in Phase I option. In Phase II, Sentient will partner with Sikorsky to further develop this flaw detection-correction technology into a closed-loop application in an AM process, and select suitable components in Army helicopter gearbox to demonstrate the developed application. It is expected that at the end of Phase II, the developed technique will meet the goal of this solicitation with an in-process method that can improve the repeatability of the material properties, geometry and quality of AM manufactured aluminum parts.

The overall goal of this project is to develop an in-process defect monitoring and correction technique for additive manufacturing (AM) of aluminum alloy to improve repeatability for geometric dimensions, material properties, and quality. In Phase I, Sentient collaborated with Johns Hopkins University Applied Physics Lab, and successfully completed all proposed tasks demonstrating two key capabilities: 1) in-situ defect monitoring capability using an infrared (IR) camera, and 2) defect correction capability using optimized AM process parameters through advanced modeling and simulation. The goal of Phase II is to develop the prototype of in-process defect monitoring and correction close-loop feedback system to optimize AM process for flaw control and defect correction. The in-situ defect monitoring capability and advanced simulation capability demonstrated in Phase I will be integrated in Matsuura LUMEX series powder bed fusion platform to demonstrate real-time close-loop feedback control capability. A comprehensive testing (e.g. microstructure, yield strength, fatigue life) will be performed on coupons made by the new AM system to demonstrate the improved part quality compared to baseline properties of as-build AM parts or conventionally sand casted parts. Finally, AM components (i.e. full-size gearbox) will be fabricated using prototype of the new AM system.