Sensing, modeling and control for laser-based additive manufacturing

Laser-Based Additive Manufacturing (LBAM) is a promising manufacturing technology that can be widely applied to part preparation, surface modification, and Solid Freeform Fabrication (SFF). A large number of parameters govern the LBAM process. These parameters are sensitive to the environmental variations, and they also influence each other. This paper introduces the research work in RCAM on improving the performance of the LBAM process. Metal powder delivery real-time sensing and control is studied to achieve a controllable powder delivery for fabrication of functionally graded material. A closed-loop control system based on infrared image sensing is built for control of the heat input and size of the molten pool in the LBAM process. The closed-loop control results show a great improvement in the geometrical accuracy of the built features. A three-dimensional finite element model is also established to explore the thermal behavior of the molten pool in the closed-loop controlled LBAM process.     

Optimization of ceramics bonding in the area of pressure sensor manufacturing

Ceramics joints are applied for producing products that should be made in a general shapes and dimensions for more advantageous usage. The article presents the research work related to ceramic joint quality evaluation, the thermal-structural analysis of ceramic joining and ceramic bond design and implementation. The role of ceramic material in the electronics industry and motivation for joining ceramics is described in the introduction. The requirements and methods for improving the quality of joints are summarized. Also, the results of simulations of pressure sensor cooling after removal from the oven during joining are discussed. The experimental results are evaluated by using a t-test before and after process cooling modification. Important directions for future research are summarized, with emphasis on the statistical determination of poor connection, and how the interface of modification of joint technology and process setting affects results and parameters that have been achieved.     

Computation and the Three Worlds

Discussions about the achievements and limitations of the various approaches to the development of intelligent systems can have an essential impact on empirically based research, and with that also on the future development of computer technologies. However, such discussions are often based on vague concepts and assumptions. In this context, we claim that the proposed `three-world ontology' offers the most appropriate conceptual framework in which the basic problems concerned with cognition and computation can be suitably expressed and discussed, although the solutions of some of these problems seem to lie beyond the horizon of our current understanding. We stress the necessity to differentiate between authentic and functional cognitive abilities; although computation is not a plausible way towards authentic intelligence, we claim that computational systems do offer virtually unlimited possibilities to replicate and surpass human cognitive abilities on the functional level.     

Parametric study on a coaxial multi-material powder flow in laser-based powder deposition process

The manner with which the composite powder particles injected into the laser formed molten pool decides the deposition quality in a typical laser-based powder deposition of composite material. Since, the morphology and physical properties of nickel (Ni) and tungsten carbide (WC) are different their powder flow characteristics such as the powder particles stream structure, maximum concentration at the converging spot, and the powder particles velocity are noticeably different. In the current study, a computational fluid dynamics (CFD) based powder flow model is established to characterize the coaxial powder flow behavior of Ni–WC composite powders. The key powder flow characteristics such as the stand-off distance, the diameter of the powder stream at the stand-off distance, and the velocity of the powder particles are measured using three different vision based techniques. Both the numerical and experimental results reveal the exact stand-off distance where the substrate needs to be placed, the diameter of the concentration spot of powder at the stand-off distance, and a combination of suitable nozzle angle, diameter, and carrier gas flow rate to obtain a maximum powder concentration at the stand-off distance with a stable composite powder flow.     

Hybrid laser-arc welding of advanced high-strength steel

This study investigated the synergetic effect between laser beam and electrical arc during hybrid welding by using a spectral diagnostic technique. The synergetic effect increased the energy density in the keyhole and deepened the weld penetration, resulting in a lower plasma electron temperature. The metal transfer mode was a globular one at a small offset distance while a spray mode was achieved with an increase in the offset distance. The decrease in the arc voltage and arc current due to the synergetic effect caused this transition from spray to globular modes. Globular transfer mode destabilized the molten pool and keyhole with the large droplet impingement, leading to the formation of porosity in the corresponding weld bead. The presence of porosity was on-line detected by identifying serious fluctuations in the Fe I electron temperature signals based on the fact that the instability of the molten pool and keyhole is strongly related to the signals coming from the plasma.     

Numerical simulation and experimental investigation of gas–powder flow from radially symmetrical nozzles in laser-based direct metal deposition

Laser-based direct metal deposition (DMD) is a solid freeform fabrication process capable of fabricating fully dense and metallurgically sound parts. The process has been greatly enhanced toward multi-directional deposition by the use of discontinuous radially symmetrical powder nozzles to supply the build material. Since many operational parameters depend on the gas–powder stream characteristics between the nozzles and the deposition point, an extensive understanding of the gas–powder flow is necessary. Three-dimensional (3D) multi-phase gas–powder flow structures of radially symmetrical nozzles are modeled using computational fluid dynamics methods. The obtained results are in good agreement with the experimental ones, and they provide a good insight into the process phenomena.     

A flexible graphical user interface for embedding heterogeneousneural network simulators

A graphical user interface (GUI) for heterogeneous neural network simulators proposed in this article is intended to be of use both for the novice and for the experienced neural network user. For the novice, it provides an easy-to-use neural network simulation package that insulates the user from the requirements of knowing the simulator implementation details or the configuration file syntax. For the experienced neural network professional it provides an interface that is easily extensible to include any additional neural network simulator in its binary form. To satisfy both academic and personal computer environments, the GUI has been developed by using the free TCL/TK software package, available on workstations running Unix and on PCs running the free Linux operating system. Although the GUI and the embedded simulators have been successfully tested both in neural network research and training programs, a more extensive testing in undergraduate and graduate level classes is in progress     

Information maximization and independent component analysis; is there a difference?

This article provides a detailed and rigorous analysis of the two commonly used methods for redundancy reduction: linear independent component analysis (ICA) posed as a direct minimization of a suitably chosen redundancy measure and information maximization (InfoMax) of a continuous stochastic signal transmitted through an appropriate nonlinear network. The article shows analytically that ICA based on the Kullback-Leibler information as a redundancy measure and InfoMax lead to the same solution if the parameterization of the output nonlinear functions in the latter method is sufficiently rich. Furthermore, this work discusses the alternative redundancy measures not based on the Kullback-Leibler information distance. The practical issues of applying ICA and InfoMax are also discussed and illustrated on the problem of extracting statistically independent factors from a linear, pixel-by-pixel mixture of images.     

Toxicity increases in ice containing monochlorophenols upon photolysis: environmental consequences

The toxic effects of photoproducts formed upon the photolysis of 2- and 4-chlorophenol (CP) frozen solutions in polycrystalline ice phase were determined with a bacterial luminescence test (Vibrio fisheri), and in vitro biomarker assay for dioxin-like effects (inductions of AhR-dependent luciferase in H4IIE-luc cells) and compared to the toxic effects of products of the same photoreaction in aquatic phase. Coupling photoproducts formed in ice samples (3'-chlorobiphenyl-2,4'-diol and 3-chlorobiphenyl-2,2'-diol from 2-CP photolysis and 5-chlorobiphenyl-2,4'-diol from 4-CP photolysis) were found to be more toxic to V. fisheri than parent CPs and elicited significant inductions of dioxin-like effects (the effective concentrations EC50 approximately 3 x 10(-5) mol L(-1) corresponded to known weaker ligands of AhR, such as nonplanar polychlorinated biphenyls or polycyclic aromatic hydrocarbons). To complete the picture, a photoproduct formed from 4-CP (5-chlorobiphenyl-2,4'-diol) was synthesized, and a detailed toxicity assessment with purified compound confirmed the results obtained with irradiated samples. Our findings support a recently proposed model according to which solar radiation can trigger the formation of new types of organic pollutants in polar ice or tropospheric ice cloud particles, presenting possibly greater risk to the environment than the parent compounds.