Inline Optical Coherence Tomography for Multidirectional Process Monitoring in a Coaxial LMD-w Process

Abstract

Within additive manufacturing, process stability is still an unsolved challenge. Process instabilities result from the complexity of laser deposition processes and the dependence of the quality of the workpiece on a variety of factors in the process. Because a stable process is dependent on many different factors, permanent precise inline monitoring is required. The suitability of the optical coherence tomography (OCT) measuring system integrated into a wire-based laser metal deposition (LMD-w) process for the task of process control results from its high resolution and high measuring speed, and from coaxial integration into the laser process, which allows for a spatially and temporally resolved representation of the weld bead topography during the process. To realize this, a spectral domain OCT (SD-OCT) system was developed and integrated into the beam path of the process laser. With the aid of suitable optics, circular scanning was realized, which allows for the 3D depth information to be displayed independently of the direction of movement of the processing head and the centrally running wire. OCT makes it possible to detect the process-typical topography deviations caused by process variations and thus paves the way for adaptive process control that could make additive laser processes more reproducible and precise in the future.

A Review on Wire-Laser Directed Energy Deposition: Parameter Control, Process Stability, and Future Research Paths

“…Based on the analysis of this data, decisions are made to compensate for any deviations from the target set point. The controller thereafter adjusts the recognized problem accordingly by modifying related parameters to enhance the part's final quality [34,46,203,204].…”