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There is growing interest in using additive manufacturing for various alloy systems and industrial applications. However, existing process development and part qualification techniques, both involve extensive experimentation-based procedures which are expensive and time-consuming. Recent developments in understanding the process control show promise toward the efforts to address these challenges. The current research uses the process mapping approach to achieve control of melt pool geometry and microstructure in different alloy systems, in addition to location specific control of microstructure in an additively manufactured part. Specifically, results demonstrate three levels of microstructure control, starting with the prior beta grain size control in Ti-6Al-4V, followed by cell (solidification structure) spacing control in AlSi10Mg, and ending with texture control in Inconel 718. Additionally, a prediction framework has been presented, that can be used to enable a preliminary understanding of melt pool geometry for different materials and process conditions with minimal experimentation. Overall, the work presented in this thesis has the potential to reduce the process development and part qualification time, enabling the wider adoption and use of additive manufacturing in industry.

Metal Additive Manufacturing (AM) promises an era of highly flexible part production, replete with unprecedented levels of design freedom and inherently short supply chains. But as AM transitions from a technology primarily used for prototyping to a viable manufacturing method, many challenges must first be met before these dreams can become reality. In order for machine users to continue pushing the design envelope, process space must be expanded beyond the limits currently recommended by the machine manufacturers. Furthermore, as usable process space expands and demands for reduced operator burden and mission-critical parts increase, in-situ monitoring of the processes will become a greater necessity. Processing space includes both the parameters (e.g. laser beam power and travel velocity) and the feedstock used to build a part. The correlation between process parameters and process outcomes such as melt pool geometry, melt pool variability, and defects should be understood by machine users to allow for increased design freedom and ensure part quality. In this work, an investigation of the AlSi10Mg alloy in a Laser Powder Bed Fusion (L-PBF) process is used as a case study to address this challenge. Increasing the range (processing space) of available feedstocks beyond those vetted by the machine manufacturers has the potential to reduce costs and reassure industries sensitive to volatile global supply chains. In this work, four non-standard metal powders are successfully used to build parts in an L-PBF process. The build quality is compared to that of a standard powder (supplied by the machine manufacturer), and correlations are found between the mean powder particle diameters and as-built part quality. As user-custom parameters and feedstocks proliferate, an increased degree of process outcome variability can be expected, further increasing the need for non-destructive quality assurance and the implementation of closed-loop control schema. This work presents two Machine Learning-based Computer Vision algorithms capable of autonomously detecting and classifying anomalies during the powder spreading stage of L-PBF processes. While initially developed to serve as the monitoring component in a feedback control system, the final algorithm is also a powerful data analytics tool – enabling the study of build failures and the effects of fusion processing parameters on powder spreading. Importantly, many troubling defects (such as porosity) in AM parts are too small to be detected by monitoring the entire powder bed; for this reason, an autonomous method for detecting changes in melt pool morphology via a high speed camera is presented. Finally, Machine Learning techniques are applied to the in-situ melt pool morphology data to enable the study of melt pool behavior during fusion of non-bulk part geometries.

Additive Manufacturing has brought about substantial benefits to the manufacturing industry due to the numerous advantages it provides, at the same time there are factors that can be improved upon. Temperature control is an important parameter during the build process as it affects build quality. The main objective of this thesis project was to investigate what sensors could be used for monitoring the temperature during the additive manufacturing processand to compare and evaluate their performance. This involved implementing two 2-color pyrometers and a short-wave infrared camera to monitor the temperature of the area behind the melt pool and then visualizing the respective data. Initial issues arose during test runs in the form of noise in the pyrometer data, this was solved by implementing a smoothing filter to the signal. Multiple runs were conducted to capture the required data as images produced by the camera were overexposed and out of focus during initial runs. This was solved by changing the camera position and exposure settings. Reading the temperature values from the images involved interpreting the Average Dark Units (ADU) values of the region of interest and then comparing those values to a reference chart. The data gathered with the help of LabVIEW software and the proprietary imaging software of the camera showed that the selected sensors were in fact suitable for the intended task and could be used in conjunction with each other. This data could then be used to create a closed-loop system in the future (not in the scope of this thesis work) and thus enable the increase in the level of automation for Robotized Laser Wire Additive Manufacturing.

Afin de proposer un outil permettant d'étudier les phénomènes hydrodynamiques dans le bain de fusion et le capillaire de vapeur lors du soudage laser, un modèle thermohydraulique prenant en compte les trois phases en présence (vapeur métallique, bain liquide et solide) a été développé à l'aide du code de calcul Comsol Multiphysics. Pour suivre l'évolution de ces trois phases, les équations couplées de la chaleur et de Navier-Stokes sont résolues et le suivi de l'interface liquide-vapeur est traité à l'aide de la méthode level set. Les réflexions multiples du laser sont calculées avec une nouvelle méthode consistant à décrire le laser sous sa forme ondulatoire. Le modèle est d’abord appliqué à un cas de tir laser statique, cas pouvant être résolu en 2D axisymétrique permettant de réaliser les développements et une première validation. L'influence de certains paramètres, comme la puissance laser est étudiée et les mécanismes conduisant à l'apparition de porosité résiduelle sont mis en évidence. Ensuite, ces mêmes équations sont utilisées en 3D pour décrire de la façon la plus complète possible une ligne de fusion. Toute la phase de création du capillaire est analysée puis les températures et les vitesses calculées sont comparées à des mesures expérimentales. Les températures en phase solide sont obtenues grâce à des thermocouples de 25µm, les températures en surface du bain liquide par pyrométrie et enfin, les vitesses à la surface du bain son obtenues grâce à une caméra rapide. Ces comparaisons permettent de montrer la cohérence du modèle, son comportement physique à décrire les écoulements, les formes de zones fondues et la dynamique du capillaire de vapeur. / To provide a tool able to study hydrodynamics phenomena in the melt pool and the vapor capillary during laser welding of tailored blanks, a heat and fluid flow model taking into account the three phases present is proposed. The metal vapor, the liquid phase and the solid base are modeled using the code Comsol Multiphysics. In order to study the evolution of these three phases, coupled equations of heat transfer and Navier-Stokes equations are solved and the liquid-vapor interface is tracked using the level set method. Multiple reflections of the laser are calculated with a new method by describing the laser in its wave form by solving Maxwell's equations. This manuscript presents the results of the model, first, in a case of a static laser shot solved in axisymmetric 2D to achieve the development and initial validation. The influence of parameters such as laser power is studied and the mechanisms leading to the appearance of residual porosities is highlighted. Then, these equations are used in three dimensions to describe the most complete as possible, a fusion line with an opened vapor capillary. All the creation phase of the capillary is analyzed. Calculated temperatures and velocities are compared to experimental measurements. Temperatures in the solid phase are obtained with thermocouples of 25µm, the surface temperature of the melt pool are obtained by pyrometry and finally velocities at the surface of the melt pool are obtained with a high speed camera. These comparisons show the consistency of the model to describe the physical flows, the molten zones shapes and the complete behavior of the vapor capillary.

Laser welding is commonly used in the automotive-, steel- and aerospace industry. It is a highly non-linear and coupled process where the weld geometry is strongly affected by the flow pattern in the melt pool. Experimental observations are challenging since the melt pool and melt flow below the surface are not yet accessible during welding. Improved process control would allow maintaining, or improving, product quality with less material and contribute further to sustainability by reducing production errors. Numerical modelling with Computational Fluid Dynamics, CFD, provides complementary understanding with access to process properties that are not yet reachable with experimental observation. However, the existing numerical models lack predictability when considering the weld shape. The work presented here is the development of a model for conduction laser welding. The solver upon which the model is based is first described in detail. Then different validation cases are applied in order to test specific parts of the physics implemented. Two cases focus on thermocapillary convection in two-phase and three-phase flows with surface deformation. Finally, a third case considers the melt pool flow during conduction mode welding.It is concluded that the convection of fusion enthalpy, which was neglected in former studies, should be included in the model. The implementation of the thermo capillary force is recommended to be consistent with the other surface forces to avoid unphysical solution. Free surface oscillations, known from experimental observations, are also computed numerically. However, further investigation is needed to check that these oscillations are not disturbed b ynumerical oscillations.

Additive manufacturing (AM) – and laser powder bed fusion (LPBF) specifically – constructs geometry that would not be possible using standard manufacturing techniques. This geometric versatility allows integration of multiple components into a single part. While this practice can reduce weight and part count, there are also serious drawbacks. One is that the LPBF process can only build parts with a single material. This limitation generally results in over-designing some areas of the part to compensate for the compromise in material choice. Over-designing can lead to decreased functional efficiency, increased weight, etc. in LPBF parts. Methods to control the material composition spatially throughout a build would allow designers to experience the full benefits of functionality integration. Spatial composition control has been performed successfully in other AM processes – like directed energy deposition and material jetting – however, these processes are limited compared to LPBF in terms of material properties and can have inferior spatial resolution. This capability applied to the LPBF process would extend manufacturing abilities beyond what any of these AM processes can currently produce. A novel concept for spatial composition control – currently under development at Brigham Young University – utilizes liquid or liquid-encased dopants to selectively alter the composition of the powder bed, which is then fused with the substrate to form a solid part. This work is focused on evaluating the feasibility and usefulness of this novel composition control process. To do this, the present work evaluates two deposition methods that could be used; explores and maps the laser parameter process space for zirconia-doped SS 316L; and investigates the incorporation of zirconia dopant into SS 316L melt pools. In evaluating deposition methods, inkjet printing is recommended to be implemented as it performs better than direct write material extrusion in every assessed category. For the process space, the range of input parameters over which balling occurred expanded dramatically with the addition of zirconia dopant and shifted with changes in dopant input quantities. This suggests the need for composition-dependent adjustments to processing parameters in order to obtain desired properties in fused parts. Substantial amounts of dopant material were confirmed to be incorporated into the laser-fused melt tracks. Individual inclusions of 100 $nm$ particles distributed throughout the melt pool in SEM images. Howewver, EDX data shows that the majority of the incorporated dopant material is located around the edges of the melt pools. Variations of dopant deposition, drying, and laser scanning parameters should be studied to improve the resulting dopant incorporation and dispersion in single-track line scans. Area scans and multi-layer builds should also be performed to evaluate their effect on dopant content and dispersion in the fused region.

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<p>Severe accidents in a Light Water Reactor (LWR) have been a subject of the research for the last three decades. The research in this area aims to further understanding of the inherent physical phenomena and reduce the uncertainties surrounding their quantification, with the ultimate goal of developing models that can be applied to safety analysis of nuclear reactors. The research is also focusing on evaluation of the proposed accident management schemes for mitigating the consequences of such accidents.</p><p>During a hypothetical severe accident, whatever the scenario, there is likelihood that the core material will be relocated and accumulated in the lower plenum in the form of a debris bed or a melt pool. Physical phenomena involved in a severe accident progression are complex. The interactions of core debris or melt with the reactor structures depend very much on the debris bed or melt pool thermal hydraulics. That is why predictions of heat transfer during melt pool formation in the reactor lower head are important for the safety assessment.</p><p>The main purpose of the present study is to advance a method for describing turbulent natural convection heat transfer of a melt pool, and to develop a computational platform for cost-effective, sufficiently-accurate numerical simulations and analyses of Core Melt-Structure-Water Interactions in the LWR lower head during a postulated severe core-melting accident.</p><p>Given the insights gained from Computational Fluid Dynamics (CFD) simulations, a physics-based model and computationally-efficient tools are developed for multi-dimensional simulations of transient thermal-hydraulic phenomena in the lower plenum of a Boiling Water Reactor (BWR) during the late phase of an in-vessel core melt progression. A model is developed for the core debris bed heat up and formation of a melt pool in the lower head of the reactor vessel, and implemented in a commercial CFD code. To describe the natural convection heat transfer inside the volumetrically decay-heated melt pool, we advanced the Effective Convectivity Conductivity Model (ECCM), which was previously developed and implemented in the MVITA code. In the present study, natural convection heat transfer is accounted for by only the Effective Convectivity Model (ECM). The heat transport and interactions are represented through an energy-conservation formulation. The ECM then enables simulations of heat transfer of a high Rayleigh melt pool in 3D large dimension geometry.</p><p>In order to describe the phase-change heat transfer associated with core debris, a temperature-based enthalpy formulation is employed in the ECM (the phase-change ECM or so called the PECM). The PECM is capable to represent possible convection heat transfer in a mushy zone. The simple approach of the PECM method allows implementing different models of the fluid velocity in a mushy zone for a non-eutectic mixture. The developed models are validated by a dual approach, i.e., against the existing experimental data and the CFD simulation results.</p><p>The ECM and PECM methods are applied to predict thermal loads to the vessel wall and Control Rod Guide Tubes (CRGTs) during core debris heat up and melting in the BWR lower plenum. Applying the ECM and PECM to simulations of reactor-scale melt pool heat transfer, the results of the ECM and PECM calculations show an apparent effectiveness of the developed methods that enables simulations of long term accident transients. It is also found that during severe accident progression, the cooling by water flowing inside the CRGTs plays a very important role in reducing the thermal load on the reactor vessel wall. The results of the CFD, ECM and PECM simulations suggest a potential of the CRGT cooling as an effective mitigative measure during a severe accident progression.</p>