About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
In-Situ Monitoring and Control of Solidification & Deformation Processes in Metal Additive Manufacturing
|
| Presentation Title |
Closed-Loop Multimodal Standoff Height Control in Directed Energy Deposition |
| Author(s) |
Callan Herberger, Thomas Feldhausen, Vladimir Orlyanchik |
| On-Site Speaker (Planned) |
Callan Herberger |
| Abstract Scope |
Laser powder directed energy deposition (LP-DED) processes suffer from inherent variability that impacts build quality, with fluctuations in melt pool dynamics and powder catchment efficiency leading to dimensional inaccuracies and material property variations. This work presents a closed-loop control framework leveraging multimodal monitoring to enable in-situ control during deposition. By integrating coaxial RGB imaging with high-frequency acoustic monitoring, continuous standoff height prediction at 50 Hz is achieved. This feedback enables dynamic standoff height adjustments, maintaining optimal powder convergence and laser focus throughout the build. Experimental demonstration on 316L stainless steel increased powder catchment efficiency by 39% and build height by 29% compared to open-loop processing. Additionally, layer height variability was reduced significantly, resulting in more consistent material deposition. The framework's modular design allows adaptation to various process parameters establishing a foundation for comprehensive in-situ control of additive manufacturing processes. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Machine Learning, Process Technology |