A Multi-view Sensor Suite/Process Model-based Control System Navy SBIR FY2010.2 Sol No.: Navy SBIR FY2010.2 Topic No.: N102-166 Topic Title: A Multi-view Sensor Suite/Process Model-based Control System Proposal No.: N102-166-0204 Firm: Stratonics, Inc. 25002 Castlewood Street Lake Forest, California 92630-3205 Contact: Holly Craig Phone: (949) 461-7060 Web Site: www.stratonics.com Abstract: 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. Benefits: Aircraft engine manufactures, UTC and others, see the need for flexible, novel approaches to understand and manage the thermal history of laser deposition processes as a means to enable the use of DDM for our commercial and military engine programs. The proposed multi?]sensor and process model?]based control system for DDM may benefit F135 and NGPF component cost and development lead?]time reductions. Future programs requiring advanced near?]net shape processing may include F135 Growth, Navy UCAS, VAATE, and LRS initiatives. Return