Project Info
Improving Quality of Wire Arc Directed Energy Deposition
Jonah Klemm-Toole
jklemmto@mines.edu
Project Goals and Description:
Powder bed fusion additive manufacturing processes are limited by small build volumes and low deposition rates. Wire arc directed energy deposition, which is essentially automated gas metal arc welding (GMAW), can provide the larger build volumes and deposition rates needed to manufacture large structural components for a wide range of applications. However, sub-optimal processing parameters can lead to gas porosity, lack of fusion porosity, or cracking, which can significantly decrease mechanical performance. The goal of this project is to understand how deposition mode and build strategy affect defects such as porosity and cracking so that they can be eliminated, thus improving build quality.
More Information:
Grand Challenge: Not applicable.
The use of wire arc directed energy deposition to make rockets can be found here: https://www.relativityspace.com/rockets
Controlling quality is obviously extremely important in space flight hardware
Primary Contacts:
Jonah Klemm-Toole (jklemmto@mines.edu)
Joe Kleindienst (josephkleindienst@mines.edu)
Sophie Hill (sophiahill@mines.edu)
Student Preparation
Qualifications
The student should be interested in welding or additive manufacturing. Experience with at least one of the following areas would be helpful: gas metal arc welding (GMAW), metallographic preparation, mechanical testing, finite element modeling or other computational simulations.
TIME COMMITMENT (HRS/WK)
4-5
SKILLS/TECHNIQUES GAINED
Depending on interest, the student can gain experience in a broad range of very useful skills for graduate school or industry. The student can work with a graduate student on wire-arc directed energy deposition process development, metallographic preparation, scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and mechanical testing. The student will be given flexibility to work on areas of interest.
MENTORING PLAN
The student will regularly meet with a graduate student in the project. Additionally, the student will participate in weekly meetings with graduate students and professor. Realistic goals will be set at the beginning of the project, and they will be continuously updated as needed. The frequent interaction with professors and graduate students will ensure all resources are being provided to ensure the student gets the most out of the project.
PREFERRED STUDENT STATUS
Sophomore
Junior
Senior