Direct temperature and quality monitoring of Laser Powder Bed fusion

9 Mar 2024
Job Information

Organisation/Company

KU Leuven

Research Field

Engineering

Researcher Profile

First Stage Researcher (R1)

Country

Belgium

Application Deadline

17 Apr 2024 - 00:00 (UTC)

Type of Contract

Temporary

Job Status

Full-time

Hours Per Week

38 hours/week

Is the job funded through the EU Research Framework Programme?

Not funded by an EU programme

Reference Number

BAP-2024-147

Is the Job related to staff position within a Research Infrastructure?

No

Offer Description

Conventional optical online monitoring of laser powder bed fusion (LPBF) is typically performed using coaxial (viewing along the laser trajectory) melt pool cameras, coaxial photo diodes, off-axis cameras, or some combination thereof. Unfortunately, the information that these techniques capture is only indirectly linked to the part quality, and complex signal processing, feature extraction, and correlation with local porosity is required. This leads to high uncertainties, while an online monitoring system should lead to more confidence on the part quality. Other non-destructive testing techniques exist that can directly measure the presence of porosities, rather than having to rely on indirect correlations. This would effectively remove an important source of the uncertainties, and would finally lead to an online monitoring system that industry would actually use. Second, online measurement of the temperature evolution during LPBF is of vital importance for the construction of digital twins of the process, and for process modeling. Such information is currently only available below the base plate with thermocouples, or on the top surface via thermal cameras. Implementing a system that can probe the temperature in various locations within a part as it is being built, without interrupting the print, would be invaluable.

The project therefore consists of two main pillars:

1) NDT part quality monitoring

• Use of existing non-destructive (non-contact) monitoring techniques, to assess their feasibility to monitor the LPBF process.

• Implementation of these sensors inside an LPBF system and on the LPBF system recoating mechanism.

• Establishing a signal processing procedure between the NDT sensor signal and part quality, and other possibly interfering effects such as surface roughness.

• A stretch goal would be the creation of control loops, that use the information of the NDT sensors to locally repair the defects.

2) Online temperature measurement

• Construction of a system that allows online part thermal history measurement in various locations of the part.

• Creation of thermal history databases upon which process models can be built.

Requirements

Research Field

Engineering

Education Level

Master Degree or equivalent

Languages

ENGLISH

Level

Good

Research Field

Engineering

Years of Research Experience

None

Additional Information
Benefits

• A doctoral scholarship (fully funded) for four years at the Department of Mechanical Engineering, and a Ph.D. degree in Engineering Science if successful.
• A remuneration package competitive with industry standards in Belgium, a country with a high quality of life and excellent health care system.
• A highly specialized doctoral training (see Arenberg Doctoral School) in an international environment at a top European university to allow you to gain the skills required to successfully complete your PhD, as well as develop yourself as an independent researcher.
• Multiple benefits (health insurance, access to university infrastructure and sport facilities, self-development through skills training courses etc.).
• The opportunity to participate in research collaborations and international conferences.
• A highly motivated group of colleagues with excellent group dynamic, stimulated through various activities organized outside of work.
• A stepping stone towards future career opportunities. KU Leuven AM group alumni have an excellent track record in pursuing both academic as well as industrial careers, both in Flanders and abroad.
• A stay in a vibrant environment in the hearth of Europe. The university is located in Leuven, a town of approximately 100000 inhabitants, located close to Brussels (25 km), and 20 minutes by train from Brussels International Airport. This strategic positioning and the strong presence of the university, international research centers, and industry, lead to a safe town with high quality of life, welcome to non-Dutch speaking people and with ample opportunities for social and sport activities. The mixture of cultures and research fields are some of the ingredients making the university of Leuven the most innovative university in Europe.

The successful candidate is expected to start on September 1st 2024 (upon agreement with Prof. Vrancken).

Eligibility criteria

• The ideal candidate is highly motivated, enthusiastic and communicative researcher with a Masters degree in Mechanical Engineering, Process Engineering, Automation Engineering, Electrical Engineering, or a closely related field. They have experience with non-destructive testing and are familiar with Additive Manufacturing processing conditions and machine hardware, or are eager to educate themselves on these topics. 
• You have obtained your degree with distinction or the equivalent thereof, and are able to work independently on this PhD project, as well as collaborate with fellow researchers in the AM group and beyond.
• Ideal candidates have experience with experimental work, (control of) manufacturing systems, sensors, data processing/other software tools (Python, Matlab, LabView, …). Specific experience with metal additive manufacturing is a plus. Furthermore, applicants should have excellent oral and written English communication skills (TOEFL score of at least 94 or IELTS-score of 7 or higher).
• The successful candidate is expected to contribute to education at the Bachelor or Master level (master thesis supervision, teaching of exercise or practical sessions, …)

Selection process

Documents required for application:

1.       Full CV – mandatory

2.       Motivation letter (maximum 1 page) – mandatory

3.       Full list of credits and grades of both BSc and MSc degrees (as well as their transcription to English if possible) – mandatory (when you haven’t finished your degree yet, provide the partial list of already available credits and grades)

4.       Proof of English proficiency (TOEFL, IELTS, …) - if available

5.       Two reference letters - if available

6.       An English version of MSc or of a recent publication or assignment - if available

Selected candidates will proceed towards an online interview, and may be asked to read a scientific publication and prepare a short presentation to present themselves, and their understanding of that paper.

For more information do not hesitate to contact Prof. dr. ir. Bey Vrancken (tel.: +32 16 19 48 65, mail: [email protected] ).

You can apply for this job no later than 17/04/2024 via the online application tool

Work Location(s)

Number of offers available

1

Company/Institute

KU Leuven

Country

Belgium

State/Province

Vlaams Brabant

City

Leuven

Postal Code

3000

Street

Leuven

Geofield

Where to apply

Website

https://easyapply.jobs/r/kjPi7Ok21veQekc4QAi

Contact

State/Province

Leuven

City

Vlaams Brabant

Street

Leuven

Postal Code

3000

STATUS: EXPIRED