Thermal imaging is an important tool for future developments in Laser Powder Deposition (LPD). Thermal imaging of the LPD process is typically used for the verification of mathematical models describing the process and/or dynamic melt pool control. The research discussed here shows how thermal imaging can be used to improve our understanding of the connection between deposition parameters, thermal gradients, and final part quality. Data gathered from melt pool and bulk-part thermal images were used to correlate deposition parameters to final part quality. The results presented here are for applications in internal barrel cladding and laser brazing.
Laser Powder Deposition (LPD) is an additive manufacturing process used for solid freeform fabrication, surface modification, and part repair or remanufacture. This technology offers some significant advantages over traditional manufacturing processes, such as reduced post-process machining and reduced material waste. Most importantly, LPD offers increased flexibility in order to meet the demands of diverse markets. However, the connection between deposition parameters, thermal gradients, and final part quality is not sufficiently understood. The research discussed here shows how radiometric temperature measurements provide insight into the connection between process parameters and final part quality. These measurements can be used to augment the research and development process while maintaining process flexibility. Radiometric thermal data was collected during the deposition of ASTM/SAE 1045, 4130, and 4140 steel thin-wall samples. Several thermal zones were identified by radiometric analysis, and compared to post-process metallographic and dimensional inspection.
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