Influence of spattering on in-process layer surface roughness during laser powder bed fusion
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Engineering↗
Engineering topics
Zhang, Haolin
Publications and source records attributed to Zhang, Haolin.
Registration and fusion of large-scale melt pool temperature and morphology monitoring data demonstrated for surface topography prediction in LPBF
In-situ monitoring technologies for laser powder bed fusion (LPBF) additive manufacturing often face one key challenge, extracting the ultrafast melt pool (MP) signatures for understanding the localized part properties. Further, the spatial information of each monitored MP signature is essential for correlating the MP – part property. This spatial information is often unavailable especially from commercial LPBF printers. Many MP monitoring methods have been reported and utilized. However, very few of these have the MP’s spatial information. To overcome this challenge, in this work we report a method for spatially registering the key MP signatures (MP intensity, temperature, and area) to the monitored print parts. The MP signatures are obtained from our coaxial high-speed single-camera based two-wavelength imaging pyrometry (STWIP) system and the MP spatial information is obtained from an off-axis camera system. A machine learning aided image analysis method is employed to retrieve the spatial distribution of MPs within the corresponding part’s coordinates system. Then, the MP signature maps (MPSMs) are reconstructed by mapping the STWIP measured MP signatures to the registered MP coordinates. Further, a long short-term memory (LSTM) neural network is developed for estimating the layer surface topography from the registered MPSMs. The obtained results indicate that the layer surface topography can be more accurately estimated by using MP temperature signature rather than MP intensity and/or area signatures as in common practice. Finally, our developed methods for MP monitoring, registration, and MP-surface topography prediction offer advanced capabilities for the online detection of process anomalies and part defects.
36 MATERIALS SCIENCE↗
The tRNA discriminator base defines the mutual orthogonality of two distinct pyrrolysyl-tRNA synthetase/tRNAPyl pairs in the same organism
Abstract Site-specific incorporation of distinct non-canonical amino acids into proteins via genetic code expansion requires mutually orthogonal aminoacyl-tRNA synthetase/tRNA pairs. Pyrrolysyl-tRNA synthetase (PylRS)/tRNAPyl pairs are ideal for genetic code expansion and have been extensively engineered for developing mutually orthogonal pairs. Here, we identify two novel wild-type PylRS/tRNAPyl pairs simultaneously present in the deep-rooted extremely halophilic euryarchaeal methanogen Candidatus Methanohalarchaeum thermophilum HMET1, and show that both pairs are functional in the model halophilic archaeon Haloferax volcanii. These pairs consist of two different PylRS enzymes and two distinct tRNAs with dissimilar discriminator bases. Surprisingly, these two PylRS/tRNAPyl pairs display mutual orthogonality enabled by two unique features, the A73 discriminator base of tRNAPyl2 and a shorter motif 2 loop in PylRS2. In vivo translation experiments show that tRNAPyl2 charging by PylRS2 is defined by the enzyme's shortened motif 2 loop. Finally, we demonstrate that the two HMET1 PylRS/tRNAPyl pairs can simultaneously decode UAG and UAA codons for incorporation of two distinct noncanonical amino acids into protein. This example of a single base change in a tRNA leading to additional coding capacity suggests that the growth of the genetic code is not yet limited by the number of identity elements fitting into the tRNA structure.
59 BASIC BIOLOGICAL SCIENCES↗
A systematic study and framework of fringe projection profilometry with improved measurement performance for in-situ LPBF process monitoring
Fringe Projection Profilometry (FPP) is a cost-effective and non-invasive technology that has been shown to measure finer features. Here, in this work, we developed an in-situ FPP method to measure the dynamic topography of powder bed and printed layer during Laser Powder Bed Fusion (LPBF) additive manufacturing (AM) process. A systematic study towards developing a comprehensive framework of LPBF-specific FPP is demonstrated to enhance and evaluate the performance of applying FPP for in-situ LPBF monitoring, including 1) a modified sensor model with localized correction; 2) improved phase unwrapping with FFT filtering 3) quantitative uncertainty analysis; and 4) experimental validation with ex-situ characterization. The developed LPBF-specific FPP system and methods are implemented on a commercial LPBF-AM machine, achieving better accuracy, more robustness, and increased field of view while maintaining sufficient measurement range and decent resolution, in contrast to literature methods. The established FPP framework will facilitate the development of closed-loop control strategies for advancing LPBF based AM.
42 ENGINEERING↗