Dimensional comparison of a cold spray additive manufacturing simulation tool

Rebecca A. Murray; Garrick Foy; L. Clemon

Dimensional comparison of a cold spray additive manufacturing simulation tool

Rebecca A. Murray, Garrick Foy, L. Clemon

Research output: Chapter in Book/Report/Conference proceeding › Conference Paper published in Proceedings › peer-review

Abstract

High-velocity particle spray greatly increases metal additive manufacturing deposition speed over other commercial methods. Accurate prediction and measurement of this process will improve process control. A LightSPEE3D machine fabricated symmetric copper components. On-board software predicts the build geometry (.stl) given the input geometry and the build settings. Assessment of prediction accuracy is needed to enable rapid part design and print setting optimization. White-light 3D-scanning and high-fidelity optical microscopy scans are compared to the simulation and intended 20mm cubes using hausdorf distance: 1. Control-repeated scans: 0.38±0.48mm, max:2.25mm 2. Intended-original vs. scans: 1.42±1.58mm, max:6.72mm 3. Software-predicted vs. scans: 0.44±0.66mm, max:3.97mm Discrepancies up to 6.72mm and asymmetric fabrication artifacts were identified. The reduction in the hausdorf distance for simulation vs intended-original, and larger distance of the simulation compared to control, indicate the simulation tool may enable rapid optimization given over/under spray quantification. Recommendations for reducing asymmetric fabrication artifacts and over/underspray are provided.

Original language	English
Title of host publication	Solid Freeform Fabrication 2019: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium
Subtitle of host publication	An Additive Manufacturing Conference
Publisher	University of Texas at Austin
Pages	1333-1339
Number of pages	7
Publication status	Published - 2019
Event	30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019 - Austin, United States Duration: 12 Aug 2019 → 14 Aug 2019

Conference

Conference	30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019
Country/Territory	United States
City	Austin
Period	12/08/19 → 14/08/19

Bibliographical note

Publisher Copyright:
© Solid Freeform Fabrication 2019: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019. All rights reserved.

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

https://utw10945.utweb.utexas.edu/2019-table-contents

Cite this

Murray, R. A., Foy, G., & Clemon, L. (2019). Dimensional comparison of a cold spray additive manufacturing simulation tool. In Solid Freeform Fabrication 2019: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium: An Additive Manufacturing Conference (pp. 1333-1339). University of Texas at Austin. https://utw10945.utweb.utexas.edu/2019-table-contents

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title = "Dimensional comparison of a cold spray additive manufacturing simulation tool",

abstract = "High-velocity particle spray greatly increases metal additive manufacturing deposition speed over other commercial methods. Accurate prediction and measurement of this process will improve process control. A LightSPEE3D machine fabricated symmetric copper components. On-board software predicts the build geometry (.stl) given the input geometry and the build settings. Assessment of prediction accuracy is needed to enable rapid part design and print setting optimization. White-light 3D-scanning and high-fidelity optical microscopy scans are compared to the simulation and intended 20mm cubes using hausdorf distance: 1. Control-repeated scans: 0.38±0.48mm, max:2.25mm 2. Intended-original vs. scans: 1.42±1.58mm, max:6.72mm 3. Software-predicted vs. scans: 0.44±0.66mm, max:3.97mm Discrepancies up to 6.72mm and asymmetric fabrication artifacts were identified. The reduction in the hausdorf distance for simulation vs intended-original, and larger distance of the simulation compared to control, indicate the simulation tool may enable rapid optimization given over/under spray quantification. Recommendations for reducing asymmetric fabrication artifacts and over/underspray are provided.",

keywords = "Cold spray, High-velocity Particle Spray, Metal Additive, Part Inspection, Scanning",

author = "Murray, {Rebecca A.} and Garrick Foy and L. Clemon",

note = "Publisher Copyright: {\textcopyright} Solid Freeform Fabrication 2019: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019. All rights reserved.; 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019 ; Conference date: 12-08-2019 Through 14-08-2019",

year = "2019",

language = "English",

pages = "1333--1339",

booktitle = "Solid Freeform Fabrication 2019: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium",

publisher = "University of Texas at Austin",

address = "United States",

}

Murray, RA, Foy, G & Clemon, L 2019, Dimensional comparison of a cold spray additive manufacturing simulation tool. in Solid Freeform Fabrication 2019: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium: An Additive Manufacturing Conference. University of Texas at Austin, pp. 1333-1339, 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019, Austin, United States, 12/08/19. <https://utw10945.utweb.utexas.edu/2019-table-contents>

Dimensional comparison of a cold spray additive manufacturing simulation tool. / Murray, Rebecca A.; Foy, Garrick; Clemon, L.
Solid Freeform Fabrication 2019: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium: An Additive Manufacturing Conference. University of Texas at Austin, 2019. p. 1333-1339.

Research output: Chapter in Book/Report/Conference proceeding › Conference Paper published in Proceedings › peer-review

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AU - Foy, Garrick

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Y2 - 12 August 2019 through 14 August 2019

ER -

Dimensional comparison of a cold spray additive manufacturing simulation tool

Abstract

Conference

Bibliographical note

UN SDGs

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