TY - JOUR
T1 - Monitoring and detection of meltpool and spatter regions in laser powder bed fusion of super alloy Inconel 625
AU - Yang, Lihang
AU - Lo, Lydia
AU - Ding, Sijie
AU - Özel, Tuğrul
N1 - Funding Information:
The prior support by the US-DOC NIST under the financial assistance number 70NANB14H227 and assistance by Dr. Shawn Moylan, Dr. Brandon Lane, and Dr. Alkan Donmez in designing and conducting experiments and acquiring in situ thermal and high frame rate videos are gratefully acknowledged.
Publisher Copyright:
© 2020, Springer Nature Switzerland AG.
PY - 2020/12
Y1 - 2020/12
N2 - Additive manufacturing is being adopted to produce metal parts directly from digital design with applications in automotive, aerospace, and biomedical products. Laser powder bed fusion (LPBF) process is a viable technology for this purpose that utilizes a high-power laser beam which follows layer-to-layer scanning of predefined paths on a metal powder bed. In situ monitoring of LPBF process is essential to detect the localized meltpool, its vicinity, and material spatter around it with a goal to control the health of the meltpool. Among many alternatives, high-fidelity video monitoring can provide cost-effective insights to the on-going process to detect changes in meltpool and its vicinity that can further be integrated into an adaptive control system. For this purpose, a high frame rate camera was employed for in situ viewing of meltpool regions during laser fusion of a super alloy, Inconel 625, powder material to be able to improve the process control capability. The size and shape of the meltpool and the heat affected region detected via in situ viewing represent the sources of information to detect possible anomalies and defects. These acquired video volumes were processed and analysed using statistical process control (SPC) charts. The results indicate that some occurrences of undermelting, overmelting, and material spatter can be detected that can then be correlated to localized defects, delamination, and layer separation.
AB - Additive manufacturing is being adopted to produce metal parts directly from digital design with applications in automotive, aerospace, and biomedical products. Laser powder bed fusion (LPBF) process is a viable technology for this purpose that utilizes a high-power laser beam which follows layer-to-layer scanning of predefined paths on a metal powder bed. In situ monitoring of LPBF process is essential to detect the localized meltpool, its vicinity, and material spatter around it with a goal to control the health of the meltpool. Among many alternatives, high-fidelity video monitoring can provide cost-effective insights to the on-going process to detect changes in meltpool and its vicinity that can further be integrated into an adaptive control system. For this purpose, a high frame rate camera was employed for in situ viewing of meltpool regions during laser fusion of a super alloy, Inconel 625, powder material to be able to improve the process control capability. The size and shape of the meltpool and the heat affected region detected via in situ viewing represent the sources of information to detect possible anomalies and defects. These acquired video volumes were processed and analysed using statistical process control (SPC) charts. The results indicate that some occurrences of undermelting, overmelting, and material spatter can be detected that can then be correlated to localized defects, delamination, and layer separation.
KW - Additive manufacturing
KW - Laser powder bed fusion
KW - Meltpool monitoring
KW - Spatter detection
KW - Super alloy
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U2 - 10.1007/s40964-020-00140-8
DO - 10.1007/s40964-020-00140-8
M3 - Article
AN - SCOPUS:85087083084
SN - 2363-9512
VL - 5
SP - 367
EP - 378
JO - Progress in Additive Manufacturing
JF - Progress in Additive Manufacturing
IS - 4
ER -