Appendix I In-Situ X-Ray and Thermal Monitoring of the Laser-Powder Bed Fusion Process: Determining Fusion Signatures Indicative of Part Quality

A NASA EPSCoR Rapid Response Research Project is being proposed by Kansas State University (KSU; the Offeror – located in an EPSCoR state) in response to Research Request Number EM21 “AM In-Situ Monitoring Data Analysis and Correlation for NDE of Part Quality” from NASA’s Marshall Spaceflight Center (MSFC). The proposed research will aid the MSFC by providing valuable experimental data representative of ‘quality fusion signatures’ obtained via in-situ X-ray imaging and thermal monitoring of the laser-powder bed fusion (L-PBF) additive manufacturing (AM) of a high-priority/program-aligning material. Quality fusion signatures are a key part to qualification and certification of L-PBF processes as dictated by NASA MSFC-STD-3716/17; thus, this Project focuses on correlating direct and salient thermal responses of the L-PBF melt pool and/or heat affected zone (HAZ) with successful fusion (i.e. no lack of fusion or pore generation). The experiment is unique in that it will be performed at the Stanford Synchrotron Radiation Lightsource (SSRL), a division of the SLAC National Accelerator Laboratory, using a custom-designed L-PBF system with an infrared (IR) camera, two-color pyrometer and high-speed visual camera. Various specimens will be built within the X-ray hutch at SSRL– collecting various images detailing melt pool formation and solidification along with pore-generating phenomena such as vapor recoil (keyholing) and spatter ejection. The X-ray data will be labeled for position and time and then correlated with IR/pyrometer image data. The goal is to predict the type and amount of porosity based on measured temperature response characteristics. This will be accomplished via deep learning and leveraging an L-PBF thermal process model. A Post-Doctoral Associate will be hired to solely work on the proposed project to ensure its success. Due to the novelty of the proposed experiments, at least two high-impact journal publications are planned.

This is a mature technology (TRL 7+) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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