group
What campus are you from?
Daytona Beach
Authors' Class Standing
Jonathan Ku, Junior Amir Yahyaeian, Graduate Student
Lead Presenter's Name
Jonathan Ku
Faculty Mentor Name
Yue Zhou
Abstract
Hybrid additive-subtractive manufacturing for aerospace metal components is an emerging approach that integrates the design flexibility of additive processes with the precision of machining. However, the effect of dwell-time modulation and machining control on the geometric performance of Cr₃C₂-NiCr-reinforced stainless steel (SS 316L) parts has not been systematically explored. This study investigates three dwell-time strategies to enhance the dimensional accuracy of laser-based directed energy deposition (L-DED) builds prior to subtractive finishing. Using a Flex Series Hybrid Manufacturing system with interchangeable toolheads, three samples were fabricated under static, exponential, and combined exponential-cubic dwell functions. The static dwell (10 s) caused heat accumulation and surface warping, while the exponential function improved dimensional accuracy. The combined exponential-cubic dwell achieved the highest geometric stability in as-built parts. Subsequent CNC milling further enhanced dimensional accuracy and surface finish. These results demonstrate that optimized dwell-time control, coupled with hybrid machining, is a critical parameter for achieving high-quality, geometrically stable ceramic-reinforced metal composites. This work advances process optimization strategies for hybrid manufacturing and contributes to improving the quality of aerospace components.
Did this research project receive funding support from the Office of Undergraduate Research.
No
Hybrid Additive-Subtractive Manufacturing of Cr3Cr2-NiCr-Reinforced Steel Composites for Spacesuit Mobility Components
Hybrid additive-subtractive manufacturing for aerospace metal components is an emerging approach that integrates the design flexibility of additive processes with the precision of machining. However, the effect of dwell-time modulation and machining control on the geometric performance of Cr₃C₂-NiCr-reinforced stainless steel (SS 316L) parts has not been systematically explored. This study investigates three dwell-time strategies to enhance the dimensional accuracy of laser-based directed energy deposition (L-DED) builds prior to subtractive finishing. Using a Flex Series Hybrid Manufacturing system with interchangeable toolheads, three samples were fabricated under static, exponential, and combined exponential-cubic dwell functions. The static dwell (10 s) caused heat accumulation and surface warping, while the exponential function improved dimensional accuracy. The combined exponential-cubic dwell achieved the highest geometric stability in as-built parts. Subsequent CNC milling further enhanced dimensional accuracy and surface finish. These results demonstrate that optimized dwell-time control, coupled with hybrid machining, is a critical parameter for achieving high-quality, geometrically stable ceramic-reinforced metal composites. This work advances process optimization strategies for hybrid manufacturing and contributes to improving the quality of aerospace components.