In Situ Process Monitoring for Additive Manufacturing Through Acoustic Techniques

Hossain, Md Shahjahan; Taheri, Hossein

doi:10.1007/s11665-020-05125-w

Cited by 58 publications

(13 citation statements)

References 52 publications

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“…[ 60,124,125 ] Other methods such as acoustic methods have also been adopted to monitor and predict defects in AM‐fabricated parts. [ 126–128 ] Acoustic monitoring has been used in process monitoring for AM of dissimilar materials, [ 126 ] and therefore can be suitable in the case of MMCs. However, due to the inherent complex phenomenon involved in L‐PBF processes, adopting single approach for defects prediction, monitoring, and control in MMCs fabrication may face series of challenges.…”

Section: An Outlook On Integrated Approach To Defects Prediction Moni...mentioning

confidence: 99%

Issues in Metal Matrix Composites Fabricated by Laser Powder Bed Fusion Technique: A Review

Essien

Vaudreuil

2022

Adv Eng Mater

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Technologies for the additive manufacturing (AM) of metals have progressed throughout the years, with significant improvements in both quality of AM components and wider scale application. In just about every current application for powder bed fusion (PBF) processes, the powders used are alloys of base metals like aluminum, iron, nickel, cobalt, and titanium, with a chemistry sometimes adapted to enable their processing by a laser-based system. While the current state of development enables the production of parts for demanding industries such as aerospace, a new class of materials such as metal matrix composites (MMCs) could enhance further applications of AM-fabricated metallic parts. MMCs combine a metallic powder with a reinforcing agent, a ceramic powder being the most commonly used. These powders can be mixed, blended, or mechanically alloyed together into a composite powder, before being consolidated layer-by-layer into the designed part. [1] This part will exhibit reinforcement particles dispersed within the bulk metal matrix. The MMCs development thus needs to achieve enhanced properties through a compromise between tenacity of the matrix and the rigidity of reinforcing particles. Figure 1 shows a schematic of processed MMC and its processing steps.The PBF process uses a high energy laser to fuse powder particles into a near net shape component. Combining different parameters (preprocessing, processing, etc.) to produce a fully dense part in AM is, however, a complex process. The consolidation process involves multiple phenomena such as heating (thermal expansion), melt pool formation, solidification, and cooling (thermal contraction), all of which occur simultaneously and in a repeated manner. [2,3] This process complexity is increased significantly when trying to attain fully dense MMC from metal and ceramic. Multiple reasons are involved, ranging from the raw materials used to interactions between laser and powder. A segregation of dissimilar materials found in the composite powder (mixed powder system) can arise on the build platform during feeding. [4] This would create issues of particles clustering and uneven dispersion, encouraging further defects formation.The capability of fabricating fully dense components with desired properties (mechanical, electrical, etc.) and less defects in AM has been the focus of researchers and industries. [5] However, inherent defects like porosities and surface roughness in AM parts remain a challenge. Various factors related to AM machines, material properties, and processing parameters are responsible for these defects.Processing parameters influence the overall quality of AM parts by influencing temperature gradients, consolidation and solidification, thermal-induced stresses as well as the susceptibility of PBF-processed part to defects. Changes in powder chemical composition can influence consolidation and defect generation. [6,7] Proper considerations must, thus, be given in understanding, predicting, and preventing defects in PBF-processed

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Section: An Outlook On Integrated Approach To Defects Prediction Moni...mentioning

confidence: 99%

Issues in Metal Matrix Composites Fabricated by Laser Powder Bed Fusion Technique: A Review

Essien

Vaudreuil

2022

Adv Eng Mater

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“…Currently, there are a variety of in-situ monitoring processes for additive manufacturing processes to identify any deviation from the optimum processing condition. These in-situ monitoring techniques include thermography, optical imaging and image processing, and acoustic techniques that have been comprehensively discussed in several review papers [5,24]. Following the identification of changes in process conditions, it is necessary to understand the influence of such deviations on the mechanical properties and potential defect generation on the parts.…”

Section: Manufacturing Process Monitoring and Quality Controlmentioning

confidence: 99%

“…These advancements and capabilities also provides the opportunity to acquire high level of details of morphology and topography of deposited AM materials [3]. Specifically, when the surface topography information is used along with the in-situ process monitoring [4,5] and defect generation mechanism [6] in AM, it provides valuable insight into understanding the AM process and quality of the parts. In additive manufacturing technology, feeding materials (usually powders or wires) are deposited on a substrate in a form of layers in a pre-defined sequence.…”

Section: Introductionmentioning

confidence: 99%

Characterization of Surface Topography Features for the Effect of Process Parameters and Their Correlation to Quality Monitoring in Metal Additive Manufacturing

et al. 2022

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Layering deposition methodology in metal additive manufacturing (AM) and the influence of different processing parameters, such as energy source level and deposition speed, which can change the melt pool condition, are known to be the important influencing factors on properties of components fabricated via AM. The effect of melt pool conditions and geometry on properties and quality of fabricated AM components has been widely studied through experimental and simulation techniques. There is a need for better understanding the influence of solidified melt pool topography on characteristics of next deposition layer that can be applied to complex surfaces, especially those with sparse topographical features, such as those that occur in AM deposition layers. Topography of deposited layers in metal additive manufacturing is a significant aspect on the bonding condition between the layers and defect generation mechanism. Characterization of the topography features in AM deposition layers offers a new perspective into investigation of defect generation mechanisms and quality evaluation of AM components. In this work, a feature-based topography study is proposed for the assessment of process parameters’ influence on AM deposition layers topography and defect generation mechanism. Titanium alloy (Ti6Al4V) samples deposited on steel substrate, by direct energy deposition (DED) AM technique at different process conditions, were used for the assessment. Topography datasets and analysis of shape and size differences pertaining to the relevant topographic features have been performed. Different AM process parameters were investigated on metallic AM samples manufactured via direct energy deposition (DED) and the potential defect generation mechanism was discussed. The assessment of the topography features was used for correlation study with previously published in-situ monitoring and quality evaluation results, where useful information was obtained through characterization of signature topographic formations and their relation to the in-situ acoustic process monitoring, as the indicators of the manufacturing process behavior and performance.

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“…AE technique was found to be a proposed method to diagnose the typical process failures of 3D printed products to be applied to more AM processes in real time. [ 22–24 ] Zhang et al [ 25 ] discussed the mechanical properties of braided composites under three‐point bending tests using AE technique. Andrew [ 26–28 ] discussed the structural properties of composites with different degrees of repair multiple times using AE monitoring techniques.…”

Section: Introductionmentioning

confidence: 99%

Flexural damage and failure behavior of 3D printed continuous fiber composites by complementary nondestructive testing technology

et al. 2022

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It is necessary to investigate the flexural damage and evolution behavior of 3D printed continuous fiber-reinforced composites. In this paper, acoustic emission technology (AE) is used to monitor the bending damage of 3D printed Kevlar fiber (KF) and glass fiber (GF)-reinforced composites in real time, and gray relational analysis (GRA) and k-means are utilized for clustering analysis of AE signals. Subsequently, micro-computed tomography (micro-CT) is employed to identify the internal damage degree. For 3D printed specimens, matrix buckling and interface failure are the main failure modes, and the number of matrix and interface damage is more than that of fiber damage, and the surface of compression side (specimen's top side) is more serious than that of the back side. KF-reinforced composites have poor delamination resistance and more serious damage than that of GF. The average maximum stress of GF and KF-reinforced specimens is 56.37 and 42.15 MPa, and the average bending modulus is 1576.42 and 1395.36 MPa, respectively. The combination of complementary detection methods is beneficial to the nondestructive evaluation and health monitoring of 3D printed composite materials.

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In Situ Process Monitoring for Additive Manufacturing Through Acoustic Techniques

Cited by 58 publications

References 52 publications

Issues in Metal Matrix Composites Fabricated by Laser Powder Bed Fusion Technique: A Review

Issues in Metal Matrix Composites Fabricated by Laser Powder Bed Fusion Technique: A Review

Characterization of Surface Topography Features for the Effect of Process Parameters and Their Correlation to Quality Monitoring in Metal Additive Manufacturing

Flexural damage and failure behavior of 3D printed continuous fiber composites by complementary nondestructive testing technology

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