Dr. Wayne King Patents Additive Manufacturing Power Map to Mitigate Overhang Structure
Background
The challenge is to build an overhang structure using AM, without formation of dross. That is how to maintain a smooth surface at the overhang. These overhang structures can differ in build quality from machine to machine due to the randomness of the dross process. There is no prior art other than trial and error, and still, this does not produce optimal overhang structure.
Dr. Wayne King’s new method uses Intelligent Feed Forward principle by employing an additive manufacturing power map an PID loop within a computational simulation. This helps maintain a constant melt pool depth, by automatically monitoring the laser energy deposition. Hence, since dross is equivalent to randomly produced melt depth that exceeds the accepted roughness threshold, the PID controls the amount of melt depth and keeps it in control, constant, hence avoiding wild fluctuations (dross) and help keep the surface smooth. The apparatus, systems and methods have use in additive manufacturing machines that use energy beams to create AM parts for any application.
Dr. Wayne King’s Patents
1. 11,433,480 : Additive manufacturing power map to mitigate overhang structure
2. 11,141,912 : Additive manufacturing powder spreading technology to mitigate surface defects
3. 10,994,337 : Controlling AM spatter and conduction
4. 10,974,456 : Additive manufacturing power map to mitigate defects
5. 6,397,682 : Intergranular degradation assessment via random grain boundary network analysis
6. 4,697,080 : Analysis with electron microscope of multielement samples using pure element standards
7. 4,162,401 : High-resolution, cryogenic, side-entry type specimen stage
Dr. Wayne King’s Bio
Dr. Wayne King is an internationally recognized leader in metal additive manufacturing, having worked in the field since 2011. He has over 30 years of experience ranging from fundamental materials research and applied science to research management. Most recently, Wayne served as project leader of the Accelerated Certification of Additively Manufactured Metals Project at Lawrence Livermore National Laboratory. This project focuses on developing physics-based models relating microstructure, properties, and process to the performance of materials and includes predictive models for the laser powder bed fusion process. The project also uses integrated in-process sensing, monitoring, and control technologies to accelerate part qualification. Wayne has developed a deep understanding of the additive manufacturing process through this work. Past work includes radiation effects, high-temperature oxidation, atomic structure of interfaces, and grain boundary engineering. Wayne is the author or co-author of over 100 peer-reviewed publications and has delivered numerous keynote lectures on the topic of metal additive manufacturing both nationally and internationally. Wayne received his B.A. degree from Thiel College in Physics and Mathematics and his Ph.D. from Northwestern University in Materials Science and Engineering.