Research Projects

The consortium aims to develop and build a CNC-based Directed Energy Deposition (DED) system that addresses major shortcomings in AM technology, particularly for fabricating gradient objects in one, two, and three dimensions. The project will develop a hybrid deposition head combining powder-based DED and wire arc additive manufacturing (WAAM) heads, with in-situ monitoring tools. This system ensures high deposition rate and the ability to build filigree structures with higher build resolution using its laser energy source. The experience of machine tool development, CNC-based hybrid DED, and process know-how will be crucial for successful deployment of the DED system at the campus facility. An in-situ process monitoring system will detect intrinsic and extrinsic process parameters resulting in process anomalies, and acoustical sensors will be used to overcome the shortcomings of state-of-the-art optical sensors. The integration of an in-situ process monitoring system to the DED system will raise the TRL level of the entire system from TRL 4 to TRL 6/7 within the project framework. Functionally Gradient Materials are aimed at being employed in multi-functional components with high wear resistance, toughness, and light weight functionality. Two types of gradients are possible: smooth gradients for coating applications, and stepped gradients for engine valves, automotive, and marine engine pistons, and large-size gears. Usage of gradient structures at specific locations reduces the employability of multiple parts and stress concentration effect, as parts will be fabricated as a single entity.