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MAE Seminar Series: “Process monitoring and modeling techniques for quality prediction and digital twin expansion in metal additive manufacturing”

January 20, 2023 @ 10:00 am - 11:00 am


Metal additive manufacturing (m-AM) process that can produce fully dense 3D structures with complex geometry using difficult-to-process metal powder or wire feedstock. Emphasis is being put on in-process monitoring and control to strengthen the quality control standard and development of digital twin for the next generation of commercial AM machines. The digital twin for m-AM is under development by unifying all simulation models (physics-based, physics-informed, data-driven, surrogate etc.) integrated with the sensory observations for bi-directional data flow powered by machine learning. Understanding the applicability of sensor integration into m-AM operation for commercial machines is critical. Furthermore, optimization of sensing techniques for m-AM environment will be crucial for better quality control. The built quality is characterized by detecting not only complex geometry but also anomalies and defects using non-destructive sensors and intelligent techniques by processing large point clouds. In-situ monitoring data are available as streaming signals, images, and videos during m-AM. In this talk, process monitoring investigations will be presented for detecting meltpool size, spattering particles, and cooling rates during laser powder bed fusion (L-PBF) process.  This presentation will also present physics-based simulation modeling for predicting the thermal field solution and molten pool geometry in L-PBF process for several popular metal powders. The numerical solution approaches that are practical and fast for computing thermal analysis and suitable for digital twin expansion in metal AM will be discussed. The talk will also present issues in microstructural refinement in wire-fed directed energy deposition (DED). High cooling rates of m-AM processes often lead to an almost exclusively columnar grains microstructure, which can result in undesirable mechanical properties. This issue can be addressed by adding of potent nuclei or a solute that promotes constitutional supercooling. A brief overview of physics-based simulation of solidification microstructure using phase field and cellular automata methods will be given for nucleation and grain refinement.

Tune in at 10 a.m. Friday, January 20, 2022 to watch live. 


Dr. Tuğrul Özel is Full Professor in the Department of Industrial and Systems Engineering and the Director of Manufacturing & Automation Research Laboratory (MARLAB) at Rutgers University- New Brunswick. He received his PhD in Mechanical Engineering from Ohio State University in 1998, BS in Aerospace Engineering from Istanbul Technical University in 1987. His research program mainly focuses on advanced manufacturing, physics-based simulation modeling, process monitoring, machine learning, laser material processing, metal additive manufacturing and machining, and bio-manufacturing. His research has been funded by NSF, DoC NIST, NASA, TTRF and industry. He was consultant for several companies including United Technologies research center and 3M Electronics & Energy. He has published over 200 research articles in journals and conference proceedings that enjoy high number of citations. He is the co-author of four edited books including “Modern Manufacturing Processes” (Wiley 2020) and “Biomedical Devices: Design, Prototyping and Manufacturing” (Wiley 2016). He is the founding Editor-in-Chief of the International Journal of Mechatronics and Manufacturing Systems, Associate Editor of the Journal of Manufacturing Science and Engineering, ASME Transactions, Journal of Manufacturing & Materials Processing and an editorial board member of several other international journals, and a member of scientific or program committee over 60 international conferences. He recently delivered several keynotes in CIRP general assemblies and international conference on Industry 4.0 and Smart Manufacturing. He is a senior member of Society of Manufacturing Engineers, American Society of Mechanical Engineers, and a former associate member of CIRP, the International Academy for Production Engineering.


January 20, 2023
10:00 am - 11:00 am
Event Category:


EB3 2236