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1. Strategies for a scalable multi-robot large scale wire arc additive manufacturing system

Author

Alex Arbogast, Andrzej Nycz, Mark W. Noakes, Peter Wang, Christopher Masuo, Joshua Vaughan, Lonnie Love, Randall Lind, William Carter, Luke Meyer, Derek Vaughan, Alex Walters, Steven Patrick, Jonathan Paul, and Jason Flamm

Subjects
Additive manufacturing, Robotics, Machine intelligence, Directed energy deposition, Coordinated robot motion, 3D printing, Industrial engineering. Management engineering, T55.4-60.8
Abstract

Conventional robotic wire arc additive manufacturing technologies enable the rapid production of moderate-sized components using low-cost wire feedstocks and robotic welding systems. Efforts to date have primarily focused on single robot solutions. However, new configurations are possible with coordination of multiple robots and multi-degree of freedom positioners. This paper describes a new multi-agent control paradigm that enables multiple robots to work collaboratively on manufacturing a single component on a rotating platform. The advantages of this approach are increased deposition rate and productivity. This paper demonstrates this control strategy on a 19 degrees-of-freedom platform based on three wire arc additive systems surrounding a single rotating platform.

Published
2024
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2. Prediction and understanding of non-linear distortion on large curved wall manufactured by wire-arc direct energy deposition

Author

Yousub Lee, Andrzej Nycz, Srdjan Simunovic, Luke Meyer, Derek Vaughan, William Carter, Sudarsanam S. Babu, Joshua Vaughan, and Lonnie Love

Subjects
Wire-arc direct energy deposition, Finite element method, Distortion mechanism, Additive manufacturing, Maintenance pauses, Industrial engineering. Management engineering, T55.4-60.8
Abstract

Wire-arc direct energy deposition (wire-arc DED) has been developed to manufacture large-scale metal products with high deposition rates, low material cost, and high material efficiency. However, dynamically varying printing conditions and complex geometries frequently lead to unfavorable part distortions during and after printing which are magnified as part sizes increase. In this study, an effective computational simulation method was developed for large-scale 316 L stainless steel parts using finite element method. The model was validated with the measured distortion using a 3D laser scanner. The distribution of deviation is within 16 % (=1.6 mm) against a measured value for a 483.6 mm tall part with 248 layers, with excellent agreement with the spatial pattern of distortion. The dynamic part deformation during printing and cooling was tracked using vision camera to investigate the thermo-mechanical deformation mechanism. The result showed that long pauses during machine maintenance pauses have strong influence on part distortion.

Published
2023
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3. Distributed manufacturing: A case study in additive manufacturing face masks for the COVID-19 pandemic

Author

Alex Roschli, Peter Wang, Christopher Hershey, Brian Post, John Lindahl, and Lonnie Love

Subjects
COVID-19, Facial respirator, Pandemic, Face mask, N95, Silicone casting, Industrial engineering. Management engineering, T55.4-60.8
Abstract

At the onset of the COVID-19 (Coronavirus Disease 2019) pandemic, USA faced supply chain issues causing a nationwide shortage of N95 respirators and PAPR devices. Researchers at Oak Ridge National Laboratory's (ORNL) Manufacturing Demonstration Facility (MDF) were sent to work from home to help slow the spread of the pandemic, and during that time they were tasked with using their manufacturing expertise to research alternative methods of producing face masks. To rapidly iterate on face mask designs without access to a research or manufacturing facility, 3D (3-Dimensional) printing and silicone casting were used. Molds and components for the masks are modeled with computer-aided design (CAD), printed with common home desktop 3D printers, and test poured with skin-safe silicone rubber. The resultant masks are form fitting and comfortable to wear. To ease the shortage of N95 filter media, the masks are designed to use existing filter materials such as home HVAC (heating, ventilation, and air conditioning) filters. The masks can be sanitized, and the filter replaced to allow the same mask to be reused. The result is not equivalent to an N95 mask, and not meant to be a replacement, but is meant to be a stopgap mask that is still able to provide the wearer filtered protection. Filtration testing has not been performed because it is not the intention of the authors to make medical claims. This research is meant to demonstrate the rapid design, iteration, and manufacturing processes of a stopgap mask.

Published
2021
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4. Effective residual stress prediction validated with neutron diffraction method for metal large-scale additive manufacturing

Author

Andrzej Nycz, Yousub Lee, Mark Noakes, Deo Ankit, Christopher Masuo, Srdjan Simunovic, Jeff Bunn, Lonnie Love, Victor Oancea, Andrew Payzant, and Chris M. Fancher

Subjects
Large-scale additive manufacturing, Finite element analysis, Residual stress, Distortion, Neutron diffraction, Materials of engineering and construction. Mechanics of materials, TA401-492
Abstract

Metal Big Area Additive Manufacturing (MBAAM), an additive manufacturing based on wire-arc process, is progressively evolving from rapid prototyping to the industrial scale production. In MBAAM, the height of printed part can easily reach eight feet, and the printing can last for hours or days. For such large printed structures, distortion and residual stress management are primary challenges in production process. Although transient thermo-mechanical simulations with very small time increments have resulted in accurate process predictions on small parts, such time resolutions are not computationally feasible for large components. Hence, the time increment in thermo-mechanical simulations of large structures needs to be evaluated with respect to simulation accuracy and computational feasibility. In this work, two thin walls were printed using MBAAM, and temperature and process parameters were recorded and used to calibrate and validate the model results. The part distortion and residual stresses were measured before and after stress relaxation by neutron beam diffraction in High Flux Isotope Reactor (HFIR). These measurements were compared to the predicted simulation results. In this work, we investigated the robustness of the computational model and the effects of time increment magnitude on the large-scale MBAAM simulations in terms of accuracy and model efficiency. We found that a coarse time increment of 20 s effectively captured the overall part distortion, but the model was not able to capture the development of residual stresses in the base plate. We determined a combination of fine and coarse time increments that offers an optimal computational efficiency and accuracy for residual stress prediction. A fine time increment of 1 s can be used to resolve the thermal interactions between the wall and base plate during the printing of the first few layers, as well as for other transitions in the geometry or process conditions. These findings provide general guidelines for selection of simulation time increments and offer a general understanding of the effect of time increments on computational efficiency and accuracy in prediction.

Published
2021
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6. Embedding Ceramic Components in Metal Structures with Hybrid Directed Energy Deposition

Author

Thomas Feldhausen, Bharat Yelamanchi, Alexander Gomez, Anton Du plessis, Kyle Saleeby, Kenton Fillingim, Brian Post, Lonnie Love, Pedro Cortes, and Eric MacDonald

Abstract

The combined benefit of both additive and subtractive manufacturing within the same gantry system enables hybrid directed energy deposition to create complex geometries with smooth surface finish and superior dimensional accuracy. Moreover, with layer-by-layer access to the structure during both the addition and subtraction of material, the insertion of components is now possible, assuming the components can survive the high temperatures associated with the subsequent metal deposition. Ceramic inserts are of interest for a variety of reasons including: (1) to create complex interwoven ductile / brittle composites for ballistics, or (2) to integrate high temperature strain or temperature sensors protected within ceramic substrate subsumed into a larger metal structure. In this work, steel substrates were machined to create an internal cavity for insertion of a ceramic component. During the investigation of several different over-the-ceramic deposition strategies, components were inserted and different sequences were continued to envelop the inserted ceramic with varying success. Unmelted powder served as both a thermal buffer and to provide a flush surface upon which the laser cladding could continue. Subsequent depositions were attempted with both dry and wet powder (addition of machining coolant to wet) providing stability and minimizing displacement caused by the gas flow. Finally, the use of an oblique angle for laser cladding allowed for the redirection of some fraction of the introduced thermal energy away from the ceramic, and consequently, improved the survival of the inserts. With this combination of techniques, ceramic inserts survived full embedding within a complex steel structure.

Published
2022
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7. 2022 roadmap on 3D printing for energy

Author

Albert Tarancón, Vincenzo Esposito, Marc Torrell, Marcel Di Vece, Jae Sung Son, Poul Norby, Sourav Bag, Patrick S Grant, A Vogelpoth, S Linnenbrink, M Brucki, T Schopphoven, A Gasser, Elif Persembe, Dionysia Koufou, Simon Kuhn, Rob Ameloot, Xu Hou, Kurt Engelbrecht, Christian R H Bahl, Nini Pryds, Jie Wang, Costas Tsouris, Eduardo Miramontes, Lonnie Love, Canhai Lai, Xin Sun, Martin Ryhl Kærn, Gennaro Criscuolo, David Bue Pedersen, and Publica

Subjects
Technology, Energy & Fuels, batteries, Materials Science (miscellaneous), Materials Science, FABRICATION, Materials Science, Multidisciplinary, fuel cells, ABSORPTION, Materials Chemistry, LITHIUM-ION BATTERY, CO2 CAPTURE, SDG 7 - Affordable and Clean Energy, Science & Technology, supercapacitors, 3D printing, SOLID OXIDE FUEL, General Energy, THERMAL MANAGEMENT, THERMOELECTRIC-MATERIALS, solar cells, TECHNOLOGIES, additive manufacturing, thermoelectrics, TOPOLOGY OPTIMIZATION, GENERATION
Abstract

The energy transition is one of the main challenges of our society and therefore a major driver for the scientific community. To ensure a smart transition to a sustainable future energy scenario different technologies such as energy harvesting using solar cells or windmills and chemical storage in batteries, super-capacitors or hydrogen have to be developed and ultimately deployed. New fabrication approaches based on additive manufacturing and the digitalization of the industrial processes increase the potential to achieve highly efficient and smart technologies required to increase the competitiveness of clean energy technologies against fossil fuels. In this frame, the present roadmap highlights the tremendous potential of 3D printing as a new route to fully automate the manufacturing of energy devices designed as digital files. This article gives numerous guidelines to maximize the performance and efficiency of the next generation of 3D printed devices for the energy transition while reducing the waste of critical raw materials. In particular, the paper is focused on the current status, present challenges and the expected and required advances of 3D printing for the fabrication of the most relevant energy technologies such as fuel cells and electrolysers, batteries, solar cells, super-capacitors, thermoelectric generators, chemical reactors and turbomachinery.

Published
2022
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9. ORNL Laboratory Directed Research and Development Program FY 2008 Annual Report

Author

Joanna McFarlane, Valmor de Almeida, Johney Green, Stuart Daw, Kalyan Chakravarthy, Sam Lewis, Scott Sluder, Bill Steele, Robert Wagner, Rolf Reitz, Gary Bell, Rick Battiste, Ralph Dinwiddie, Sam Sham, Panos Datskos, Nickolay Lavrik, Barton Smith, Viviane Schwartz, Costas Tsouris, Claus Daniel, Leon Tolbert, Madhu Chinthavali, Burak Ozpineci, Fran Li, John Kueck, Michael Starke, Hui Zhang, Yan Xu, David DePaoli, Alicia Compere, William Griffith, Chaitanya Narula, Arpad Vass, Luis Sanchez, Joel McDuffee, Jess Gehin, Randy Hobbs, Larry Ott, Lance Snead, Donald Spellman, Dennis Heatherly, Ronald Ellis, Kenneth Thoms, Sheng Dai, Huimin Luo, Gary Baker, Todd Toops, C. Britton, G. Alley, M. Ericson, R. Warmack, S. Retterer, Glenn Young, Bernadetta Srijanto, Chad Duty, Ron Ott, Philip Boudreaux, Adrian Sabau, Gerald Jellison, Curt Maxey, Keith Leonard, Biswajit Das, Volker Urban, Kunlun Hong, Phillip Britt, Jimmy Mays, Alexander Boeker, Miroslaw Gruszkiewicz, Ariel Chialvo, David Cole, Michael Simonson, Douglas Goeringer, Gary Van Berkel, Vilmos Kertesz, William Whitten, Robert Shaw, G. Stocks, Amit Goyal, Jianxin Zhong, Yanfei Gao, Albina Borisevich, Niels Jonge, Andrew Lupini, Stephen Pennycook, Gabriel Veith, Ho Lee, Matthew Chisholm, David Singh, Sergei Kalinin, Gilbert Brown, Ilia Ivanov, Stephen Jesse, David Hoelzer, James Bentley, Chong Fu, Michael Miller, Xingqiu Chen, Xun-Li Wang, Benjamin Hay, Jeremy Jackson, David Geohegan, Gernot Rother, Petro Maksymovych, Vincent Meunier, J. Wendelken, Zhenyu Zhang, Gyula Eres, M. Paranthaman, Baohua Gu, Wenguang Zhu, A. Buchanan III, Michelle Kidder, Reza Dabestani, Edward Hagaman, Minghu Pan, John Ankner, Mark Dadmun, S. Kilbey II, John Simpson, Nancy Dudney, Karren More, Ed Hagaman, Bob Shaw, De-en Jiang, Andrew Payzant, Edgar Lara-Curzio, Charles Collier, Seung-Yong Jung, Scott Retterer, Zhiyu Hu, Mark Buckner, Michael Moore, Michael Vann, Nageswara Rao, Lawrence MacIntryre, Miljko Bobrek, Benjamin Huey, Donald Bouldin, A. Qualls, B. Sumpter, S. Labinov, John Neal, Lynn Boatner, Slobodan Rajic, Mallikarjun Shankar, Yu Jiao, Ryan Kerekes, Rick Lusk, Thomas Potok, Timothy Rhyne, Vladimir Protopopescu, William Heller, Yiming Mo, Dean Myles, Greg Smith, Eugene Mamontov, Peter Cummings, Kenneth Herwig, Louis Santodonato, J. Ankner, J. Mays, J. Messman, D. Myles, B. Lokitz, Liyuan Liang, Wei Wang, Alex Johs, Hugh O’Neill, Edward Snell, Chris Tulk, Antonio Dos Santos, Jamie Molaison, Bryan Chakoumakos, Juske Horita, Dave Cole, Robert Welton, F. Baity, Richard Goulding, Andrew Christianson, Sheila Baker, Mark Lumsden, Stephen Nagler, Brian Sales, Thomas Schulthess, Thomas McManamy, Roy Crawford, Phillip Ferguson, James Janney, Mark Rennich, Leighton Coates, Flora Meilleur, Randy Fishman, Lee Robertson, Jian Shen, Wei-Ren Chen, Gregory Smith, William Goddard, Yi Liu, Yun Liu, Lionel Porcar, Pratul Agarwal, Edward Michaud III, Carmen Foster, Martin Keller, Zamin Yang, Amudhan Venkateswaran, Mircea Podar, Christopher Schadt, Steven Brown, Shihui Yang, Timothy Tschaplinski, Dale Pelletier, Gregory Hurst, Yunfeng Yang, Udaya Kalluri, Timothy McKnight, Jennifer Morrell-Falvey, Patricia Lankford, Sara Jawdy, A. Borole, Anthony Palumbo, Nance Ericson, Jeremy Smith, Elissa Chesler, Virginia Dale, Latha Baskaran, Budhendra Bhaduri, Robin Graham, Richard Middleton, Patrick Mulholland, Esther Parish, Alexandre Sorokine, Amy Wolfe, Thomas Wilbanks, Auroop Ganguly, Anthony King, David Erickson, Keith Kline, Sherry Wright, Hector Castro-Gonzalez, Marie De Graaff, Charles Garten III, Aimee Classen, Paul Hanson, Stan Wullschleger, Richard Norby, Kenneth Childs, Warren Thomas, Brynn Voy, Ram Datar, Olaf Storaasli, Edoardo Apra, Jerzy Bernholc, Robert Harrison, William Shelton, Bobby Sumpter, Sudharshan Vazhkudai, John Cobb, Xiaosong Ma, Stephen Scott, Hong Ong, Christian Engelmann, Geoffroy Vallee, Ricky Kendall, Ron Brightwell, Barney Maccabe, T. Schulthess, M. Eisenbach, D. Nicholson, X. Tao, C. Zhou, J. Levesque, Andrey Gorin, Nabeela Ahmad, Andrew Bordner, Jessie Gu, Guruprasad Kora, Chongle Pan, Byung-Hoon Park, Nagiza Samatova, Xiuping Tao, Edward Uberbacher, Kalyan Perumalla, Sudip Seal, Jeffrey Vetter, Srikanth Yoginath, Srdjan Simunovic, Phani Nukala, Kevin Clarno, Ian Gauld, Theodore Besmann, Charles Weber, Warren Grice, Ryan Bennink, Philip Evans, Travis Humble, David Bernholdt, Richard Barrett, Wael Elwasif, Aniruddha Shet, John Drake, J. White III, R. Archibald, J. Drake, K. Evans, D. Kothe, P. Worley, Jim Kohl, Doug Lepro, Dude Neergaard, Thomas Maier, Gonzalo Alvarez, Jeremy Meredith, Michael Summers, Mark Bannister, Robert Hettich, Charles Vane, Charles Havener, Herbert Krause, Michael Fogle, Jr., David Schultz, Robert Continetti, Mats Larsson, Richard Thomas, Mitchel Doktycz, David Allison, Thomas Thundat, Christopher Rey, Abhijeet Borole, Ali Passian, Yisong Wang, Yie Liu, Henry Lin, Boyd Evans, Siyang Zheng, Jason Fowlkes, Philip Rack, James Lee, Barbara Evans, Peter Reilly, Elias Greenbaum, Sylvia McLain, David Baker, Chengdu Liang, Jane Howe, Jun Xu, Radu Custelcean, Steve Overbury, Seth Cohen, Richard Ward, Kara Kruse, James Nutaro, Barbara Beckerman, Oscar Grandas, Xiaohui Cui, B. Radhakrishnan, X.-G. Zhang, An-Ping Li, N. Kulkarni, Shannon Mahurin, Meng-Dawn Cheng, David Gossage, Bruce Wilson, T. Yin, L. Gunter, Ken Littrell, Hassina Bilheux, D. Bjornstad, A. Wolfe, Jeff Warren, Timothy Bigelow, John Caughman, John McKeever, Philip Ryan, Matthew Scudiere, Gary Alley, Nagraj Kulkarni, Hsin Wang, Harry Meyer, Bala Radhakrishnan, Don Nicholson, Peter Todd, Kenneth Tobin, Vincent Paquit, Jeffery Price, John Jansen, Lonnie Love, Peter Lloyd, Christopher Mann, Philip Bingham, John Biggerstaff, Michael Zemel, Brian D’Urso, Randy Lind, Justin Baba, Seung Lee, S. Rajic, P. Datskos, Fernando Reboredo, Chengjun Sun, Xiaoguang Zhang, David Mandrus, C. Narula, M. Moses-DeBusk, A. Buchanan, C. Hsueh, P. Becher, C. Liu, John Wang, Narendra Dahotre, Seokho Kim, Peter Blau, Steve Pawel, Hans Christen, Joachim Schneibel, Michael Brady, Terry Tiegs, John Vitek, J. Horton, Ken Liu, Dan Naus, I. Wright, Lance. Snead, Thak Byun, Roger Miller, B. Bischoff, K. Adcock, Evan Ohriner, Donald Erdmann III, Katyayani Seal, James Haynes, Bruce Pint, Pengcheng Dai, Zheng Gai, Lifeng Yin, Y. Melnichenko, G. Wignall, D. Cole, A. Radlinski, M. Mastalerz, C. Alexander, R. Smithwick, L. Lewis, L. Boatner, Juan Ferrada, Jack Collins, Les Dole, Charles Forsberg, M. Haire, Rodney Hunt, Ben Lewis, Ray Wymer, Jennifer Ladd-Lively, Michael Hu, Lei Shao, Hatice Akkurt, Keith Eckerman, Ida Lee, Sotira Yiacoumi, Daniel Hollenbach, D. Dean, M. Ramsey-Musolf, Michael Smith, Eric Lingerfelt, Kim Buckner, and Caroline Nesaraja

Subjects
Engineering, Aeronautics, business.industry, Annual report, business
Published
2009
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