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Wire-feed laser additive manufacturing is an emerging fabrication technique capable of highly automated large-scale volume production that can reduce both material waste and overall cost while improving product lead times. Quality assurance is necessary for implementation into critical structural applications. However, the large number of process variables along with the cost associated with traditional trial and error methods makes this difficult. This study investigates a comprehensive quality framework based on learning from experimental data that will enable improved quality control along with consistent microstructural features of the part. Specifically, a comprehensive experimental data across multiple process variables and output characteristics in terms of overall bead quality, geometric shape (i.g. bead height, width, fusion zone depth, etc.), and microstructural features are collected. The predicted process-geometry-microstructure relations are then captured by virtue of data-driven machine learning models. The properties of printed beads are visualized based on an extensive range of processing space within a 3-dimensional contour map. The insights and impacts of process variables on bead morphology, geometric and microstructural features are comprehensively investigated for quality improvement during manufacturing processes.
Wire-feed laser additive manufacturing (WLAM) is gaining wide interest due to its high level of automation, high deposition rates, and good quality of printed parts. In-process monitoring and feedback controls that would reduce the uncertainty in the
The advancement of machine learning promises the ability to accelerate the adoption of new processes and property designs for metal additive manufacturing. The molten pool geometry and molten pool temperature are the significant indicators for the fi
Many emerging applications in microscale engineering rely on the fabrication of three-dimensional architectures in inorganic materials. Small-scale additive manufacturing (AM) aspires to provide flexible and facile access to these geometries. Yet, th
A thick electrode with high areal capacity has been developed as a strategy for high-energy-density lithium-ion batteries, but thick electrodes have difficulties in manufacturing and limitations in ion transport. Here, we reported a new manufacturing
An experimental investigation of sub-wavelength imaging by a wire medium slab is performed. A complex-shaped near field source is used in order to test imaging performance of the device. It is demonstrated that the ultimate bandwidth of operation of