| Abstract Scope |
First time quality with Arc-DED is needed for high-mix and low-volume applications for building and cladding features, and repairing casting, forging, and wrought components. Commercial real-time monitoring and control systems are needed that provide machine, pool and deposit analysis to ensure first-time quality. Significant challenges include poor bead fusion from inadequate process deposition models for range of features, inconsistent layer height from deposition model volume variances, and distortion in multi-plane build geometries. Fully functional “lights-out” arc-DED quality monitoring and control systems are needed to help minimize operator interaction with the machine while providing confidence that near net shape parts will meet the quality standards for surface and volumetric NDE. Through a National Shipbuilding Research Program (NSRP), this project is developing and supporting DED qualification of a commercial supplier. This includes development of an arc-DED system, quality management system, and final procedure qualification for nickel aluminum bronze (NAB) marine components. As a part of this program, the RAMLAB’s Max-Q sensor is being developed for dimensional management on robots that use Autodesk PowerMill computer aided modeling DED software. The Max Q sensor uses a compact scanner, high resolution camera, and infrared camera. The Max-Q system is being developed to integrate machine, pool and deposit sensing for first-time quality. This includes development of fusion models for deposit quality, and scan to plan adaptive deposition models for layer to layer dimensional control using a PowerMill-based build plan variance analysis. Lessons learned, practical applications, and development next steps will be discussed for Max Q system implementation on DED applications. |