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Meeting 2026 TMS Annual Meeting & Exhibition
Symposium In-Situ Monitoring and Control of Solidification & Deformation Processes in Metal Additive Manufacturing
Presentation Title Accelerating Directed Energy Deposition (DED) Adoption Through In-Situ Data Collection and Closed-Loop Processing Control
Author(s) Melanie Lang, Jeffrey Riemann
On-Site Speaker (Planned) Melanie Lang
Abstract Scope While additive manufacturing offers the promise of groundbreaking design freedom, qualification remains a significant bottleneck. In-situ monitoring—using tools like melt-pool imaging, pyrometry, and profilometry—for real-time insights into defects and process stability is increasingly recognized as an integral part of the AM process. Many early systems implementations offered static reporting capabilities, and there is growing industry-wide recognition of the need to advance toward closed-loop, adaptive systems to reduce defects, accelerate qualification, and enable microstructural control during fabrication. Toward this, we are introducing here an in-situ closed-loop processing monitoring and control system initially released and under continual advancement since 2016. In this discussion we will explore how closed-loop control and data logging is used to accelerate parameter development and optimization for alloy development and Functionally Graded Materials (FGM) using DED technology.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Machine Learning, Process Technology

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

'Simulation Twins' - Sensing and Control of Unseen Quantities Through Real-Time Assimilation of Imaging to FEA
Accelerating Directed Energy Deposition (DED) Adoption Through In-Situ Data Collection and Closed-Loop Processing Control
Alloy Design and Microstructure-Property Relationships for Non-Equiatomic Ti-Zr-Nb-Ta-V-Cr Alloys With Tensile Ductility Made by Laser Powder Bed Fusion
Closed-Loop Multimodal Standoff Height Control in Directed Energy Deposition
Effects of Forging on Microstructural and Mechanical Properties of AISI 316LSi Fabricated via Wire Arc Additive Manufacturing (WAAM)
Enabling Low-Latency Synchrotron XRD Analysis for Real-Time Insights Into Driven Microstructural Evolution
F-56: Directed Energy Deposition of a Medium Manganese Steel: Influence of Processing Parameters on Microstructure and Mechanical Properties
F-57: Dynamics of Intermetallic Phase Formation During Additive Manufacturing of Functionally Graded Aluminium-Titanium
F-58: Microstructural Origins of Tensile Anisotropy and Deformation Behaviour in Additively Manufactured SS201 Stainless Steel
Heat and Beat: New Strategies for Dislocation Density Control in Steels During Laser Powder Bed Fusion
High-Throughput In-Situ Ultrasonic Monitoring of Melt Pool Dynamics and Phase Transformations in Laser Additive Manufacturing
High-Throughput Process–Structure–Property Mapping in LPBF of 316L via In Situ Monitoring and Automated Characterization
In-Situ Monitoring and Closed-Loop Control of Stainless Steel 316L Direct Energy Deposition via Plasma Plume Dynamics
Infrared Imaging and Multiphysics Modeling for Prediction of Solidification Dynamics During Selective Laser Melting
Machine Learning Guided Exploration of Process-Structure-Property Relationships in Metal Additive Manufacturing
Predicting Deposition Height and Properties in Directed Energy Deposition
Processing-Microstructure-Mechanical Behavior Relationships in Ferrous Alloys via Mixed Powder Laser Powder Bed Fusion
Revealing Optimal Melting Regimes for Defect Lean Thin-Walled Aluminium Laser Powder Bed Fusion Builds
Size Effects in Mechanical Properties of LPBF SS316L
Sub-Surface Temperature Evolution Mapping During Laser Powder Bed Fusion via In-Situ XRD
Tailoring Microstructure and Mechanical Properties During Additive Manufacturing of Ti-6Al-4V via In-Process Laser Heat Treatments
Tailoring Phase Transformation and Residual Stress in Wire-DED via Thermal Sensing and Multiphysics Modeling
Tracking Phase Evolution in Additive Manufacturing of Steels via Operando X-Ray Diffraction
Understanding Microstructure Evolution During Processing in Additively Manufactured Functionally Graded Materials

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