STRATONICS INC — Department of Defense SBIR Phase I: Stratonics, Inc. proposes to demonstrate the feasibility of measuring critical variable pa

Description

Stratonics, Inc. proposes to demonstrate the feasibility of measuring critical variable parameters and controlling thermal conditions in direct digital manufacturing (DDM) by developing a multi-sensor/process model-based control system. The innovation combines a multi-view thermal imaging sensor suite, finite element method (FEM) model and real-time software algorithms to control the laser power, deposition position, and powder feed of laser material deposition processes. Stratonics successful development of DDM thermal control will prevent defects/flaws (voids, lack of fusion, porosity because of too cold a process) or inhomogeneous deposits (chemical variation due to excessive melting or vaporization, and variation of microstructure within a part). The imaging sensors will view the melt pool along the laser axis to provide thermal measurements and will also view the deposit from the side. These measurements will be used as input to the FEM process model, which will be accurately calibrated to make intelligent control decisions. DDM System variable parameters will be controlled to produce the required changes in the process to achieve desirable deposit metallurgy. Stratonics has formed a strong team of experts, including Penn and Ohio State Universities and industrial partners, Optomec, Pratt & Whitney and Morris Technologies, all leaders in additive manufacturing technologies.