About this Abstract |
| Meeting |
2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
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| Symposium
|
2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
|
| Presentation Title |
In-Situ Acoustic Emission-Based Powder Flow Monitoring for Precise Functionally Graded Materials via Powder-Blown Laser Directed Energy Deposition |
| Author(s) |
Rowan Faith Leialoha Rolark, Rujing Zha, Jon-Erik Mogonye, Jian Cao |
| On-Site Speaker (Planned) |
Rowan Faith Leialoha Rolark |
| Abstract Scope |
Powder-blown Laser Directed Energy Deposition (L-DED) is a promising technology for fabricating complex material blends through the simultaneous deposition of multiple powdered alloys. However, achieving precise compositional grading remains a challenge, as conventional methods rely on offline, averaged powder flow measurements and fixed feed rates, which fail to capture local variations in powder flow and are inherently incompatible with real-time control. Here, we implemented an in-situ powder flow monitoring system in a custom L-DED setup, utilizing piezoelectric acoustic emission sensors to detect powder particle impact across multiple powder lines. Generated acoustic emission signals were correlated with empirical powder flow measurements for calibrated real-time monitoring and on-the-fly tuning of multiple alloy feed rates. The accuracy of as-built gradients was evaluated via EDS mapping and compared against target elemental compositions. This work builds a critical foundation for closed-loop control in L-DED, paving the way for the fabrication of high-precision, functionally graded materials. |
| Proceedings Inclusion? |
Planned: Post-meeting proceedings |