A program to implement real-time sensing and control of spray-formed preform conditions is underway at the David Taylor Research Center. The objective of the program is to develop sensor and control technologies that can be used to monitor critical process conditions and modify operational parameters during the spray forming of components. This task has been divided into two phases. The first entails developing sensors and controls to monitor and correct simulated process conditions. In the second phase, the selected sensors and controls will be combined with actuators, thereby integrating research center equipment and enabling the production of nonsymmetric preforms.

Developing intelligent control for spray forming processes

In this paper, the results of a recent study designed to improve our understanding of the hardness, tensile properties, cyclic fatigue response, and fracture characteristics of a spray-atomized and deposition-processed Al-Cu-Mg-Ag Alloy are presented. Specimens of the alloy were deformed to failure at ambient temperature under both quasi-static and cyclic stress amplitude-controlled conditions. The hardness, tensile properties, high-cycle fatigue response, and fracture characteristics of the alloy are compared with a conventional ingot metallurgy-processed counterpart and discussed in light of intrinsic microstructural effects, nature and magnitude of loading, and ductility of the microstructure.

Microstructure and Mechanical Properties of A Spray-Atomized and Deposited Al-Cu-Mg-Ag Alloy

: A program to implement real time sensing and control of spray formed preform conditions is underway at the David Taylor Research Center. The objective of the program is to develop sensor and control technology to monitor the critical process conditions and to modify parameters during the spray forming process to produce components with repeatable microstructural quality. This task has been divided into two phases, the first of which entails development of sensors and controls to monitor and correct simulated process conditions. In the second phase, the selected sensors and controls will be combined with actuators for integration with the DTRC equipment to allow for the production of nonsymmetric preforms.

http://www.dtic.mil/cgi-bin/GetTRDoc?AD=ADA226499&Location=U2&doc=GetTRDoc.pdf

Intelligent Processing for Spray Metal Manufacturing

: A control system incorporating a fuzzy logic inference engine and optical sensors has been developed for the spray forming facility at the David Taylor Research Center An imaging system employing laser illumination and a high speed CCD camera provides critical on-line preform surface roughness and rate of growth information A fuzzy logic controller utilizes a rule set to translate visual information into a form that can be reviewed by the conditional statements of the rule base A high performance manipulator and motion controller have also been incorporated into the spray forming system This discussion includes development of optical sensors and integration of advanced control systems to determine and activate required corrective actions to the spray forming process parameters

An intelligent control strategy for the spray forming process

: Spray forming in the Osprey mode is a process in which gas atomized molten metal droplets are interrupted in flight by impingement on a substrate to form a relatively thick deposit The overall objective of this research program is to develop a fundamental processing science base for the process To this end, concurrent experimental and modeling studies focus on droplet velocity and temperature profiles, the mechanism(s) of droplet-substrate interactions, droplet spreading on impact and droplet solidification, and the relationship between process parameters and microstructural integrity of the deposit On-going experimental studies are reviewed and some preliminary results of the modeling work are presented

A Fundamental Study of Droplet Impingement, Spreading and Consolidation.

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A Fundamental Study of Droplet Impingement, Spreading and Consolidation.