Monitoring of Laser Consolidation Process of Metal Powder with High Speed Video Camera

Furumoto, Tatsuaki; Alkahari, Mohd Rizal; Ueda, Takashi; Aziz, Mohd Sanusi Abdul; Hosokawa, Akira

doi:10.1016/j.phpro.2012.10.098

Cited by 55 publications

(25 citation statements)

References 11 publications

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“…Multiple interesting works were found looking at high speed visible-spectrum imaging of the L-PBF process on custom systems [18], [19], and on commercial systems [20], which use active illumination to image the melt pool. This technique provides very high speed, high contrast images of the melt pool and is the most effective means for visualizing and measuring melt pool size and dynamics.…”

Section: Introductionmentioning

confidence: 99%

Thermographic measurements of the commercial laser powder bed fusion process at NIST

Lane

Moylan

Whitenton

et al. 2016

RPJ

143

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Measurement of the high-temperature melt pool region in the laser powder bed fusion (L-PBF) process is a primary focus of researchers to further understand the dynamic physics of the heating, melting, adhesion, and cooling which define this commercially popular additive manufacturing process. This paper will detail the design, execution, and results of high speed, high magnification in-situ thermographic measurements conducted at the National Institute of Standards and Technology (NIST) focusing on the melt pool region of a commercial L-PBF process. Multiple phenomena are observed including plasma plume and hot particle ejection from the melt region. The thermographic measurement process will be detailed with emphasis on the ‘measurability’ of observed phenomena and the sources of measurement uncertainty. Further discussion will relate these thermographic results to other efforts at NIST towards L-PBF process finite element simulation and development of in-situ sensing and control methodologies.

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Section: Introductionmentioning

confidence: 99%

Thermographic measurements of the commercial laser powder bed fusion process at NIST

Lane

Moylan

Whitenton

et al. 2016

RPJ

143

View full text Add to dashboard Cite

show abstract

“…[77][78][79][80][81], the authors use a system consisting of a camera and a pyrometer to monitor the temperature of the melt pool. In Refs.…”

Section: Pbf Processesmentioning

confidence: 99%

“…te r ia l Publications[38,46,[56][57][58][59][60]63,66,[70][71][72]74,76,87,88,91,113,118,119,137,148,154,[172][173][174]176,177] [29,45,60,62,80,81,84,89,99,[107][108][109]118,120,131,132,141,149,154,155,184] [24,25,27,…”

mentioning

confidence: 99%

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

Tapia

Elwany

2014

Journal of Manufacturing Science and Engineering

574

188

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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.

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“…It determines the structural properties of the solidified material and influences the residual stress as well as thermal deformation. 1,2 From the perspective of manufacturing quality, information about the temperature of the melt pool could indicate how well the final product has been manufactured. Deviations could be analyzed and corrective action could be taken as soon as they are detected.…”

Section: Introductionmentioning

confidence: 99%

Process observation in fiber laser–based selective laser melting

2014

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Abstract. The process observation in selective laser melting (SLM) focuses on observing the interaction point where the powder is processed. To provide process relevant information, signals have to be acquired that are resolved in both time and space. Especially in high-power SLM, where more than 1 kW of laser power is used, processing speeds of several meters per second are required for a high-quality processing results. Therefore, an implementation of a suitable process observation system has to acquire a large amount of spatially resolved data at low sampling speeds or it has to restrict the acquisition to a predefined area at a high sampling speed. In any case, it is vitally important to synchronously record the laser beam position and the acquired signal. This is a prerequisite that allows the recorded data become information. Today, most SLM systems employ f -theta lenses to focus the processing laser beam onto the powder bed. This report describes the drawbacks that result for process observation and suggests a variable retro-focus system which solves these issues. The beam quality of fiber lasers delivers the processing laser beam to the powder bed at relevant focus diameters, which is a key prerequisite for this solution to be viable. The optical train we present here couples the processing laser beam and the process observation coaxially, ensuring consistent alignment of interaction zone and observed area. With respect to signal processing, we have developed a solution that synchronously acquires signals from a pyrometer and the position of the laser beam by sampling the data with a field programmable gate array. The relevance of the acquired signals has been validated by the scanning of a sample filament. Experiments with grooved samples show a correlation between different powder thicknesses and the acquired signals at relevant processing parameters. This basic work takes a first step toward self-optimization of the manufacturing process in SLM. It enables the addition of cognitive functions to the manufacturing system to the extent that the system could track its own process. The results are based on analyzing and redesigning the optical train, in combination with a real-time signal acquisition system which provides a solution to certain technological barriers. © The Authors. Published by SPIE under a Creative Commons Attribution 3.0 Unported License. Distribution or reproduction of this work in whole or in part requires full attribution of the original publication, including its DOI.

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Monitoring of Laser Consolidation Process of Metal Powder with High Speed Video Camera

Cited by 55 publications

References 11 publications

Thermographic measurements of the commercial laser powder bed fusion process at NIST

Thermographic measurements of the commercial laser powder bed fusion process at NIST

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

Process observation in fiber laser–based selective laser melting

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