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Ontology-based Process Map for Metal Additive Manufacturing

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Abstract

Additive manufacturing (AM) is a layer-by-layer material deposition process that allows for more manufacturing flexibility and design complexity than traditional manufacturing processes. However, the print quality in metal AM is hard to be predicted and controlled due to its high process variability. Numerous process parameters are correlated/intertwined and have a direct/indirect relationship with the final build quality. However, these interconnections among the process parameters and print qualities are not yet fully understood and identified. To achieve a functional part without additional post-processing to improve the surface finish/mechanical properties, the comprehensive process model, which includes the semantic and qualitative connections among the process inputs-signatures-qualities, is urgently needed. Currently, surrogate models (regression models/ physical-based models) are widely used for predicting part qualities, specifically thermal distortion. These surrogate models can provide a simulated result based on the user-defined parameter settings. However, the reverse determination of the highly correlated parameters that can manage the print qualities in the desired standard cannot be achieved through these surrogate models. Understanding this interconnectivity is the top priority in building process models that will help to make the process more predictable and controllable. An ontology-based process map that captures the complicated metal AM processes, including all input parameters, physical, thermal model, and resultant build qualities (microstructure and mechanical properties), is provided in this manuscript. The connections among these factors are used to diagnose the relevant process variables regarding the specific build qualities, which can further combine with experimental data to contribute to a “printable” zone. The ontology-based process map links variable selection to quality requirements, creating a printable zone. A printable zone indicates the allowable process parameter selections, contributing to the desired part quality. Ultimately, the selected variable process data from the ontological process map will scope the parametrical analysis. The implementations of the ontology-based process map and printable zone are presented to demonstrate this proposed method's effectiveness by demonstrating that the proposed printable zone's validity and desired build quality can be achieved.

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Acknowledgments

This work was supported by NIST Grant 2014-NIST-MSE-01 and a cooperative agreement between the National Institute of Standards and Technology (NIST) and The Pennsylvania State University.

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Authors and Affiliations

  1. Department of Mechanical Engineering, The Pennsylvania State University, University Park, PA, 16802, USA

    Byeong-Min Roh & Timothy W. Simpson

  2. Department of Industrial and Manufacturing Engineering, University Park, PA, 16802, USA

    Soundar R. T. Kumara & Timothy W. Simpson

  3. National Institute of Standards and Technology (NIST), Gaithersburg, MD, 20899, USA

    Paul Witherell

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Correspondence to Timothy W. Simpson.

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This invited article is part of a special topical focus in the Journal of Materials Engineering and Performance on Additive Manufacturing. The issue was organized by Dr. William Frazier, Pilgrim Consulting, LLC; Mr. Rick Russell, NASA; Dr. Yan Lu, NIST; Dr. Brandon D. Ribic, America Makes; and Caroline Vail, NSWC Carderock.

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Roh, BM., Kumara, S.R.T., Witherell, P. et al. Ontology-based Process Map for Metal Additive Manufacturing. J. of Materi Eng and Perform 30, 8784–8797 (2021). https://doi.org/10.1007/s11665-021-06274-2

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