The overall objective of the NSERC HI-AM Network is to provide realistic and transferable solutions for the foremost challenges preventing industry from converting their conventional manufacturing methods into metal AM processes. Attaining this goal through HI-AM’s research activities will:
Secure Canadian leadership in the AM sector.
Develop, optimize, and implement new feedstock materials, AM process models and simulations, monitoring sensors and closed-loop control systems, and novel AM processes/products.
Forge lasting relationships between academic institutions, public and private industrial organizations, local and federal governments, and international collaborators.
HI-AM researchers and their partners are working to improve the quality of additively manufactured parts, process reliability and performance, cost efficiency, and scalability for the following standard metal AM processes:
Directed Energy Deposition (DED)
Powder-Bed Fusion (PBF)
Binder Jetting (BJ)
The research program proposed by HI-AM is working toward these goals within 4 themes, through 14 projects and 39 sub-projects with objectives directly relevant to the research needs of our partner organizations and the research scopes proposed by NSERC in its strategic target areas. These integrative, multidisciplinary, and transdisciplinary research themes include:
Theme 1: Material Development Tailored with Optimum Process Parameters
Theme 2: Advanced Process Modeling and Coupled Component/Process Design
Theme 3: In-Line Monitoring/Metrology and Intelligent Process Control Strategies
Theme 4: Innovative AM Processes and AM-made Products
HI-AM uses an adaptive management approach, wherein knowledge from each theme will be incorporated within all other themes, in order to achieve the Network goals.
The goal of this theme is to create, test and standardize feedstock metal and metal alloys to broaden the scope of metal parts that can be easily and cost effectively adapted to metal AM processes.
Project 1.1: Development of Next Generation Alloys
Sub-project 1.1.1) Development of thermally stable aluminum alloys for LPB-AM
Sub-project 1.1.2) Development of titanium alloys for LPF-AM and LPB-AM
Sub-project 1.1.3) Development of tool steels for LPB-AM and LPF-AM
Sub-project 1.1.4) Development of nickel alloys for LPB-AM
Sub-project 1.1.5) Development of refractory metals for LPB-AM
Project 1.2: AM processing of multi-material systems
Sub-project 1.2.1) Novel composites for BJ-AM to develop foam-based structures
Sub-project 1.2.2) Alloy alteration for functionally graded materials (FGMs) used in LPF-AM
Project 1.3: Cost reduction strategies
Sub-project 1.3.1) Recyclability of powder feedstock for LPB-AM
Sub-project 1.3.2) Plasma spheroidization of low cost powders
Sub-project 1.3.3) Cost-effective feedstock
The goal of this theme is to develop novel, robust, and efficient numerical models that will become the new tools for simulating different aspects of the Laser- and electron-beam-based PBF and DED processes, along with melt-feedstock interactions and its effects on the finished parts.
Project 2.1: Multi-scale modeling of AM
Sub-project 2.1.1) Beam-powder/melt pool interaction and energy transport: experimental validation
Sub-project 2.1.2) Meso-scale thermal field evolution in melt pool substrate
Sub-project 2.1.3) Macro-scale thermal field evolution
Sub-project 2.1.4) Macro-scale stress field evolution
Sub-project 2.1.5) Microstructural modeling and experimental validation
Sub-project 2.2.1) Fast process thermal-field simulation
Sub-project 2.2.2) Fast process stress-field simulation
Project 2.3: Pre-processing for optimization of AM process parameters
Sub-project 2.3.1) Pre-processing for dimensional control
Sub-project 2.3.2) Lattice structure design for AM processing
Sub-project 2.3.3) Component build geometry optimization for AM processing
The goal of this theme is to develop novel in- and off-line quality assurance protocols to establish the relationship between in-process feedback data and post-process part characterization. Machine learning algorithms, along with sophisticated monitoring and metrology devices, will effectively monitor defects and disturbances in real-time allowing for adjustments in process parameters through advanced controllers. The end result will push AM technology toward “Certify-as-you-build” platforms.
Project 3.1: Innovative in-situ and ex-situ monitoring strategies for AM-made product quality analysis
Sub-project 3.1.1) Development of non-contact dynamic melt pool characteristic measurement via radiometric monitoring for LPB-AM and LFF-AM
Sub-project 3.1.2) Development of continuous and layer-intermittent imaging capabilities for LPF-AM, LPB-AM, and BJ-AM
Sub-project 3.1.3) Develop non-contact capability to detect sub-surface properties using eddy current inductive measurements
Sub-project 3.1.4) Laser ultrasonic sensing for LPB-AM and LPF-AM
Project 3.2: Real-time control and machine learning algorithms for laser powder-bed and powder-fed AM processes
Project 3.3: Intelligent closed-loop control of compaction density for LPB-AM processes
Sub-project 3.3.1) Measurement system development and validation of combined powder spread linked with sintering model
Sub-project 3.3.2) Closed-loop control of compaction density and experimental validation
Project 3.4: Process-based adaptive path planning protocols for LPF-AM
Sub-project 3.4.1) Combined trajectory optimization and thermal analytical models
Sub-project 3.4.2) Adaptive path planning protocols/controllers and experimental validation
The goal of this theme is to use the fundamental knowledge generated in Themes 1 to 3 to accelerate the development of innovative metal AM process parameters and finished-part performance roadmaps that can be certified to ensure the quality and repeatability of AM built parts.
Project 4.1: Innovative AM processes with integrated magnetic systems
Sub-project 4.1.1) Magnetically driven vacuum-based powder delivery processing head for LPF-AM