THIS IS THE RAPID CONFERENCE IN ORLANDO IN MAY 2016
I DIDN'T NOTICE SIGMA LISTED HERE UNDER: "STATE OF THE ART IN PROCESS MONITORING AND SAFETY ASSURANCE" ...at 2:30 PM
((Is this something different than us...similar??? ))
COULD ONE OF YOU ADDITIVE MANUFACTURING GENIUSES SHED SOME LIGHT ON THIS PLEASE? THANKS!!!
Quality & Inspection
Tuesday, May 19
2:00 pm – 4:25 pm
2:00 pm – 2:25 pm
Metrology Meets Additive Manufacturing
Christiane Beyer Dr.-Ing., Associate Professor, California State University Long Beach & Rohit Khanna, President, 3D InfoTech
The innovative combination of: a) methods and tools in the field of Metrology, which includes all theoretical and practical aspects of measurements, and b) Additive Manufacturing (AM), offers the potential for the acceptance of 3D printed parts in automotive, aerospace, medical, biotechnology, consumer product marketplace, and many other industries. One of the current challenges of the applied research is to move away from the monitoring of production processes and parameters and move towards an intuitive and traceable quality control and management system. Making the research even more challenging is the capability of AM technologies to produce highly complex and multi-functional parts with cavities and complicated lattice structures. The presentation will describe the advantages and possibilities of Additive Manufacturing technologies. It will address the existing difficulties in quality control and explain why the implementation of quality management systems and standards is important to industrial leaders, engineers, researchers, educators, and government officials. It will introduce applicable approaches and implementation of methods and tools of Metrology shown on case studies. It will also explain necessary strategic implications of adequate quality standards for a widespread adoption of Additive Manufacturing.
2:30 pm – 2:55 pm
Additive Metals: State-of-the-Art in Process Monitoring and Safety Assurance
Zach Murphree PhD, Sales Engineer, Concept Laser Inc.
This presentation will highlight QMmeltpool 3D RT and QMmeltpool RT, which provide real-time in-situ monitoring of the meltpool intensity and shape to detect build aberrations as they occur, and to provide a virtual 3D CT scan of the built parts with unparalleled resolution. QMcoating RT provides closed-loop control of the recoater system to ensure a precise, even powder distribution in a specific area of interest, reducing powder usage and the occurrence of failed builds due to short-feeds. While the quality of the parts coming out of the machine is critical, operator safety is the single most important consideration. With this in mind, the presentation will also detail Concept Laser’s safety consciousness, including our adherence to ATEX guidelines for explosive atmospheres and our patented filter-change method that allows the filter to be passivated without ever removing the filter from an inerted environment.
3:00 pm – 3:25 pm
Non-Destructive Inspection (NDI) of Electron Beam Direct Manufacturing (EBDM) of Titanium
Kevin Klug PhD, Fellow Engineer, Concurrent Technologies Corporation
Emerging AM technologies such as EBDM are considered vital to improve affordability and reduce lead times associated with traditional manufacturing technologies. A major challenge to introducing AM components into the F-35 supply stream is the development and acceptance of required non-destructive inspection (NDI) methodologies and standards to ensure the resulting product meets quality and design requirements. A Navy Metalworking Center (NMC) project is evaluating the effectiveness of traditional and advanced NDI techniques (including traditional radiography (RT), standard ultrasonics (UT), fluorescent penetrant inspection (FPI) and computed tomography (CT) methods) to establish standardized NDI processes and procedures for production of EBDM titanium components. This paper builds on the RAPID 2014 presentation, by detailing results subsequently obtained under the NMC project. These include NDI and metallographic observations from notional and prototype components containing both intentionally implanted and naturally occurring defects. This project is funded by the U.S. Defense Manufacturing Science & Technology’s Industrial Base Innovation Fund and the Navy ManTech Program, and is being executed by an Integrated Project Team (IPT) consisting of Lockheed Martin Aeronautics – Advanced Development Programs, Sciaky, Inc., Joint Strike Fighter Joint Program Office, Air Force Research Laboratory (AFRL), Naval Air Systems Command and NMC.
3:30 pm – 3:55 pm
Ultrasonic Nondestructive Inspection of Ti-6Al-4V Produced Using Electron Beam Directed Energy Deposition
Shawn Kelly PhD, Applications Engineer/Director AMC, EWI
Post-process non destructive inspection (NDI) of metallic components produced by additive manufacturing processes is a necessary step in the quality control process, especially for critical components. Conventional NDI techniques such as ultrasonic inspection can be used for inspection of relatively simple geometries produced by electron beam directed energy deposition (EB-DED) processes. The inspection of materials such as Ti-6Al-4V produced using electron beam directed energy deposition processes presents an additional challenge due to the metallurgical features that develop during production. The effect of EB-DED process changes on microstructure, and the impact of these microstructures on the ability to detect defects using ultrasonic inspection techniques will be discussed.
4:00 pm – 4:25 pm
Real Time Defect Detection on New Generation Electron Beam Manufacturing Systems for Quality Assurance
Francisco Medina PhD, Senior Specialist, Materials Development, Arcam/ORNL
Electron Beam Melting is a novel additive manufacturing technology that selectively consolidates metal powders to fabricate 3D structures from digital data in a layer-by-layer fashion. EBM has been shown to be capable of fabricating high-volume, high-value components with reduced lead times. The new generation of Arcam’s EBM systems are equipped with high resolution cameras that acquire images of each layer, after the layer has been completed. The camera can take a picture of the full build area and has a pixel resolution of 100 micros. The new imaging system can also be used as a calibration tool for machine setup and operation. New software is being developed with collaboration from ORNL MDF to create a 3D model of the structured build with the acquired images. It has been proven with CT scanning, the imaging system can accurately detect features in the process and can be used as a quality control tool.
