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Meeting MS&T22: Materials Science & Technology
Symposium Additive Manufacturing: Equipment, Instrumentation and In-Situ Process Monitoring
Presentation Title Challenges and Opportunities for In-Situ Sensing during Electron Beam Powder Bed Fusion Additive Manufacturing
Author(s) Tim Horn
On-Site Speaker (Planned) Tim Horn
Abstract Scope Electron Beam Powder Bed Fusion (EB-PBF) Additive Manufacturing has demonstrated applicability for a variety of materials, including high-temperature refractory metals and crack-prone nickel superalloys, as well as control over local microstructures. However, the benefits of rapid fabrication and microstructural control are overshadowed by long certification times associated with the prediction, measurement, and mitigation of defects at different physical scales. Therefore, in-situ techniques that yield a layer-by-layer spatial distribution of defects have generated significant interest. However, for EB-PBF, key challenges exist. Sensors must be resistant to metallization, heat, powder contamination, and x-ray damage. In this presentation, we will provide a review of the recent literature and industrial application of salient sensing technologies for EB-PBF with a highlight on recent work toward the collection and interpretation of in-situ backscattered electron data. We will discuss the capabilities and limitations of each approach in the context of recent advances in materials and applications.

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A-18: Development of an IEP Apparatus for 3D Printing of Thermoelectric Material
A-19: In-process Microstructure Sensing of Gr91 Powder Bed Fusion Parts Using Ultrasonics
A-20: Real-time Process Monitoring for Multivariate Statistical Process Control in Powder Bed Fusion Metal Additive Manufacturing
A-21: Quantification of Melt Pool Variability for L-PBF Additive Manufacturing by High-Speed Imaging
Additive Manufacturing Standardization Landscape and Recent Initiatives Advancing Standards Development
Additive Materials Data: Truths and Myths
AM Materials Data – Challenges and Opportunities
An Intelligent Data Infrastructure for Additive Manufacturing
Automated Detection and Quantification of Spatter Generated During Laser Powder Bed Fusion Using Infrared Imaging and Computer Vision
Challenges and Opportunities for In-Situ Sensing during Electron Beam Powder Bed Fusion Additive Manufacturing
Characterization of Laser Powder Bed Fusion Internal and Surface Defects as a Foundation for In Situ Monitoring
Design of a Glovebox for In Situ Monitoring of a Directed Energy Deposition Process
Exploring Synchronized Dual Laser Scan Strategies for Increased Productivity of Laser Powder Bed Fusion
High-Speed Thermal Imaging of the Melt Pool in Laser Powder Bed Fusion
In-situ Monitoring of the EBM Process: From Powder Bed Homogeneity to Thermal Signatures
In-situ Process Monitoring of Laser Powder Bed Fusion Additive Manufacturing Using Thermionic Emission Detection
In-situ Process Monitoring, Synchronization and Mapping Laser Powder Bed Fusion Builds of Ti6Al4V
In-situ Sensor Feature Engineering for Process Development of Energy Conversion Materials
Instrumenting an EOS M290 with a Smart Build-Plate
Investigating the Use of In-situ Weld Pool Characteristics and Temperature Measurements for Monitoring Part Quality in Wire Arc Additive Manufacturing
Melt Pool-Scale Process Monitoring of Laser Powder Bed Fusion
Microstructure Control during Wire and Arc Additive Manufacturing
New Standardization Efforts to Collect, Correlate, and Identify Metrics of Reuse Powder with Functional Performance Data of Material Resultant of Additive Manufacturing Workflows
Optimization of Laser Powder Bed Fusion AM through Process Gas Control 
Process Monitoring of Melt Pool Spatter at Melt Pool, Layer and Part Scales
Providing a Rigorous Benchmark Measurement Foundation for Modeling-Informed Qualification and Certification of Metal AM Components
Real-time, High-speed and High-resolution Multi- and Hyperspectral Imaging of Powder Bed Fusion
Research and Standards Development Needs for AM Industrialization
Role of Interstitial Alloying Elements on Microstructural Evolution in Additively Manufactured Materials
Scientific Foundations and Approaches for Qualification of Additively Manufactured Structural Components
Several Ways Ultrasound Can Be Used during Powder Bed Fusion
Using High-Speed Thermal Imaging to Understand Melt Pool Defects in Laser Powder Bed Fusion
Wire DED Process Monitoring and Controls

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