MRI: Development of a Five-Axis Rapid Metal Forming System

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This grant provides funding for the research and development of a five-axis rapid metal forming facility using laser applied metal processing. The equipment will utilize a wire feeding system to improve the speed and accuracy of depositing metal. Integration software will be developed for automated generation of process planning for five-axis direct metal process. The facility will be capable of directly producing metal prototypes and parts from both ferrous and non-ferrous alloys. Research and development activities will include developing and optimizing multi axis path planning for a five-axis metal forming system; vision-based processing for control of laser deposition; intelligent path planning and control of laser deposition machines; studies of deposition factors determining part microstructure; process control for optimizing quality of rapidly formed metal parts; studies of transport phenomena to improve laser deposition quality; and applying the direct metal forming process to allow for rapid product realization. This project will result in the ability to rapidly form metal prototypes. Designers will be able to generate CAD drawings of a near-net shape part with functionally graded materials to match design requirements and then use this equipment to directly produce a metal prototype within a few hours. If successful, the parts will be produced with high accuracy and excellent reproducibility. The microstructure and properties of the parts can be optimized during the deposition process. This will provide a benefit to many manufacturers that require rapid metal prototypes such as the tool and die industry where lead times are traditionally several weeks. The will benefit manufacturers by shortening product development cycle times and delivering better products to market. The integrated educational and research training activities will bring cutting-edge science and technology to the classroom.