Dynamic Optimization of Directed Energy Deposition Build Conditions Using Real-Time Monitoring Via Closed-Loop Control

Directed Energy Deposition (DED) is an additive manufacturing process that is being rapidly adopted by industry and is well suited for the fabrication of complex components in various metal alloys. DED provides unique benefits such as design flexibility, the potential for in-situ alloying, and an open environment that allows for unobstructed monitoring within the build chamber. Despite these benefits, fully exploiting additive manufacturing's (AM) potential remains a complex task for designers. This dissertation presents a framework for controlling Directed Energy Deposition process variables through in-situ monitoring. An exploration into modifying AM build conditions through the development and implementation of a multimodal model using real-time closed-loop control. Leveraging data from visual and acoustic sensors to detect deviations in the build process, enabling immediate adjustments to process parameters. Real-time closed loop feedback increases stability to build conditions and improves consistency. By correlating visual and acoustic signals with the weld pool, this research establishes a novel methodology for real-time standoff height estimation and adaptive layer height control. The dissertation evaluates the effectiveness of the designed closed-loop control system, demonstrating its capability to adapt the manufacturing process based on immediate feedback from the monitoring systems. By improving the reliability and efficiency of AM processes, this work contributes to their broader adoption in industrial applications to increase quality and yield.