A review of in-situ monitoring and process control system in metal-based laser additive manufacturing

Cai, Yuhua; Xiong, Jun; Chen, Hui; Zhang, Guangjun

doi:10.1016/j.jmsy.2023.07.018

Cited by 42 publications

(3 citation statements)

References 120 publications

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“…Liu [20] notes that suboptimal scanning patterns exacerbate uneven melting and cooling, leading to significant surface irregularities and dimensional discrepancies. Additionally, the intricacies of metallurgy and the interrelated nature of defects make DED a challenging process to monitor and control [21][22][23].…”

Section: Introductionmentioning

confidence: 99%

Advances in Ultrasonic-Assisted Directed Energy Deposition (DED) for Metal Additive Manufacturing

Zhang,

Xu,

et al. 2024

Crystals

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Directed Energy Deposition (DED), a branch of AM processes, has emerged as a significant technique for fabricating large metal components in sectors such as aerospace, automotive, and healthcare. DED is characterized by its high deposition rate and scalability, which stand out among other AM processes. However, it encounters critical issues such as residual stresses, distortion, porosity, and rough surfaces resulting from rapid melting and solidification. As a novel advancement, Ultrasonic-Assisted Directed Energy Deposition (UA-DED) integrates ultrasonic oscillations into DED aimed at addressing these challenges. Herein, the latest research related to the UA-DED process and the current major challenges of the DED process, residual stresses, porosity, and crack defects are critically reviewed. Subsequently, the paper also details the working principle and system components of UA-DED technology and reviews the material improvement by introducing UA into the DED process, grain, porosity, tensile properties, and deposition defects. The most critical optimization methods of process parameter variables for UA and the different material interaction mechanisms between UA and DED processes are identified and discussed in detail. Finally, the perspectives on the research gap and potential future developments in UA-DED are also discussed.

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Section: Introductionmentioning

confidence: 99%

Advances in Ultrasonic-Assisted Directed Energy Deposition (DED) for Metal Additive Manufacturing

Zhang,

Xu,

et al. 2024

Crystals

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“…Direct laser deposition technology often employs open-loop fabrication with fixed process parameters. These parameters are typically set through a combination of materials, models, and machines, and then manually adjusted through extensive experimental evaluations and analyses to enhance processing accuracy [9] . However, this open-loop control mode lacks process monitoring.…”

Section: Introductionmentioning

confidence: 99%

Real-time closed-loop control of molten pool transient area in direct laser deposition via PID algorithm with enhanced robustness

Liu,

Xia

et al. 2024

Int J Adv Manuf Technol

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In the direct laser deposition (DLD) process, it is common to employ constant processing parameters. The utilization of the constant parameters may lead to fluctuations in the dynamic evolution of the molten pool, primarily due to the intricate thermal effects involved, which will significantly impact the processing quality. To address this issue, this study proposed a closedloop control approach that effectively modifies processing parameters in real-time by targeting on the molten pool transient area. The most suitable processing parameter to control the molten pool area was found to be the laser power by a set of orthogonal experiments. Then the dynamic response relationship between laser power and the molten pool area was mathematically characterized by a third-order transfer function model to simplify the complex physical model of the DLD process. Subsequently, a PID controller with a filtering coefficient and anti-windup compensation was chosen compared with the other controller. In the validation experiments, it was observed that the closed-loop processing group demonstrated improved stability in maintaining the molten pool transient area, with a notable decrease of 33.7% in variability compared to the open-loop processing group. As a result, the deposited layer of the closed-loop processing group exhibited a much more satisfying surface quality and heat affect zone than the open-loop group. This study provides a fundamental basis for improving the consistency of the direct laser deposition processing quality through the implementation of real-time feedback control of molten pool physics.

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“…In material management, more flexible integrated material handling systems are being used (e.g., OneClick Metal, Mprint & Mpure cartridge system). Further, more straightforward post-processing and quality assurance are sought after through the use of, for example, support-minimizing designs [8], effective support removal technologies, and in-process quality monitoring systems [9]. Some recently introduced methods for improving productivity are laser spot size [10] and beam shape manipulation together with laser defocus and skin/core strategies [11].…”

Section: Introductionmentioning

confidence: 99%

Metal Laser-Based Powder Bed Fusion Process Development Using Optical Tomography

Björkstrand,

Akmal,

Salmi

2024

Materials

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In this study, a set of 316 L stainless steel test specimens was additively manufactured by laser-based Powder Bed Fusion. The process parameters were varied for each specimen in terms of laser scan speed and laser power. The objective was to use a narrow band of parameters well inside the process window, demonstrating detailed parameter engineering for specialized additive manufacturing cases. The process variation was monitored using Optical Tomography to capture light emissions from the layer surfaces. Process emission values were stored in a statistical form. Micrographs were prepared and analyzed for defects using optical microscopy and image manipulation. The results of two data sources were compared to find correlations between lack of fusion, porosity, and layer-based energy emissions. A data comparison of Optical Tomography data and micrograph analyses shows that Optical Tomography can partially be used independently to develop new process parameters. The data show that the number of critical defects increases when the average Optical Tomography grey value passes a certain threshold. This finding can contribute to accelerating manufacturing parameter development and help meet the industrial need for agile component-specific parameter development.

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A review of in-situ monitoring and process control system in metal-based laser additive manufacturing

Cited by 42 publications

References 120 publications

Advances in Ultrasonic-Assisted Directed Energy Deposition (DED) for Metal Additive Manufacturing

Advances in Ultrasonic-Assisted Directed Energy Deposition (DED) for Metal Additive Manufacturing

Real-time closed-loop control of molten pool transient area in direct laser deposition via PID algorithm with enhanced robustness

Metal Laser-Based Powder Bed Fusion Process Development Using Optical Tomography

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