Dimensional comparison of a cold spray additive manufacturing simulation tool

Rebecca A. Murray, Garrick Foy, L. Clemon

    Research output: Chapter in Book/Report/Conference proceedingConference Paper published in Proceedingspeer-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 languageEnglish
    Title of host publicationSolid Freeform Fabrication 2019: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium
    Subtitle of host publicationAn Additive Manufacturing Conference
    PublisherUniversity of Texas at Austin
    Pages1333-1339
    Number of pages7
    Publication statusPublished - 2019
    Event30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019 - Austin, United States
    Duration: 12 Aug 201914 Aug 2019

    Conference

    Conference30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019
    Country/TerritoryUnited States
    CityAustin
    Period12/08/1914/08/19

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