A Review on Process Monitoring and Control in Metal-Based Additive Manufacturing

Abstract

There is consensus among both the research and industrial communities, and even the general public, that additive manufacturing (AM) processes capable o f processing metal lic materials are a set o f game changing technologies that offer unique capabilities with tremendous application potential that cannot be matched by traditional manufacturing technologies. Unfortunately, with all what AM has to offer, the quality and repeatability o f metal parts still hamper significantly their widespread as viable manufacturing proc esses. This is particularly true in industrial sectors with stringent requirements on part quality such as the aerospace and healthcare sectors. One approach to overcome this challenge that has recently been receiving increasing attention is process monitoring and real-time process control to enhance part quality and repeatability. This has been addressed by numerous research efforts in the past decade and continues to be identified as a high priority research goal. In this review paper, we fill an important gap in the liter ature represented by the absence o f one single source that comprehensively describes what has been achieved and provides insight on what still needs to be achieved in the field o f process monitoring and control fo r metal-based AM processes.

The manufacture of honeycomb cores using Fused Deposition Modeling

“…10 Each method has advantages and disadvantages, as discussed in Refs. 11,12 An oft-highlighted issue with AM is the difficulty in quality control 6,[13][14][15][16] ; Huang et al 16 present a thorough review of quality control in AM. Process parameter optimization allows design for improvements in manufacturing, as in, 17 and improved mechanical proper-ties.…”

Integration of physically-based and data-driven approaches for thermal field prediction in additive manufacturing

“…Seppala and Migler were interested in the cooling rate near newly extruded region and investigated the weld zone properties through side view IR thermography [92]. As summarized in [93], one of the key advantages in applying pyrometry is to collect temperature without physical contact, which makes it possible to monitor surfaces of any geometry. Besides, another important advantage is to minimize the potential degradation of the sensor.…”

Additive manufacturing of materials: Opportunities and challenges

“…Popular approaches 21 to in situ monitoring include tracking spatial and temporal surface variations through optical techniques 22 and temperature measurements using one-or two-dimensional (2D) pyrometers and thermocouples and displacement sensors. 23 Here, we highlight two methodologies for inspecting and monitoring the electron beam melting (EBM) powder-bed manufacturing process.…”