Adaptive vision-based detection of laser-material interaction for directed energy deposition

Naiel, Mohamed A.; Ertay, Deniz Sera; Vlasea, Mihaela; Fieguth, Paul

doi:10.1016/j.addma.2020.101468

Cited by 6 publications

(4 citation statements)

References 40 publications

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“…The culmination of this process involved utilizing the processed images to accurately estimate the melt pool's height in real-time, demonstrating a significant advancement in monitoring and controlling the DED process. Naiel et al [190] conducted experiments using five different power levels to rigorously investigate the impact of various melting modes, such as under-melting and keyhole melting, on the size of the melt pool, by utilizing a vision camera to accurately monitor any variations in the melt pool size. Perani et al [191] developed a vision-based monitoring system for the DED molten pool by utilising a laser coaxial CMOS camera that could accommodate the entire melt pool, due to its 400 × 400 pixel size.…”

Section: Vision-based Signalsmentioning

confidence: 99%

Advancements in 3D Printing: Directed Energy Deposition Techniques, Defect Analysis, and Quality Monitoring

Imran,

Che Idris,

De Silva

et al. 2024

Technologies

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This paper provides a comprehensive analysis of recent advancements in additive manufacturing, a transformative approach to industrial production that allows for the layer-by-layer construction of complex parts directly from digital models. Focusing specifically on Directed Energy Deposition, it begins by clarifying the fundamental principles of metal additive manufacturing as defined by International Organization of Standardization and American Society for Testing and Materials standards, with an emphasis on laser- and powder-based methods that are pivotal to Directed Energy Deposition. It explores the critical process mechanisms that can lead to defect formation in the manufactured parts, offering in-depth insights into the factors that influence these outcomes. Additionally, the unique mechanisms of defect formation inherent to Directed Energy Deposition are examined in detail. The review also covers the current landscape of process evaluation and non-destructive testing methods essential for quality assurance, including both traditional and contemporary in situ monitoring techniques, with a particular focus given to advanced machine-vision-based methods for geometric analysis. Furthermore, the integration of process monitoring, multiphysics simulation models, and data analytics is discussed, charting a forward-looking roadmap for the development of Digital Twins in Laser–Powder-based Directed Energy Deposition. Finally, this review highlights critical research gaps and proposes directions for future research to enhance the accuracy and efficiency of Directed Energy Deposition systems.

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Section: Vision-based Signalsmentioning

confidence: 99%

Advancements in 3D Printing: Directed Energy Deposition Techniques, Defect Analysis, and Quality Monitoring

Imran,

Che Idris,

De Silva

et al. 2024

Technologies

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show abstract

“…However, this mechanism does not apply to the DED process which has a larger laser spot size and a lower energy density than LPBF. Hence DED is normally in conduction mode with no keyhole 2 , 39 , has a much larger molten pool 40 , 41 , and includes powder bombardment 42 which can contribute to different bubble evolution and melt pool dynamics. In DED, Wolff et al 5 reported pore formation mechanisms as a result of powder delivery, keyhole dynamics, melt pool dynamics and shielding gas in Ti-6Al-4V using a piezo-driven powder delivery DED system; however, the energy density used was much greater than many industrial-scale DED builds with a keyhole formed, and hence some of the phenomena observed were more typical of the LPBF process.…”

Section: Introductionmentioning

confidence: 99%

Pore evolution mechanisms during directed energy deposition additive manufacturing

Zhang,

Chen,

Marussi

et al. 2024

Nat Commun

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Porosity in directed energy deposition (DED) deteriorates mechanical performances of components, limiting safety-critical applications. However, how pores arise and evolve in DED remains unclear. Here, we reveal pore evolution mechanisms during DED using in situ X-ray imaging and multi-physics modelling. We quantify five mechanisms contributing to pore formation, migration, pushing, growth, removal and entrapment: (i) bubbles from gas atomised powder enter the melt pool, and then migrate circularly or laterally; (ii) small bubbles can escape from the pool surface, or coalesce into larger bubbles, or be entrapped by solidification fronts; (iii) larger coalesced bubbles can remain in the pool for long periods, pushed by the solid/liquid interface; (iv) Marangoni surface shear flow overcomes buoyancy, keeping larger bubbles from popping out; and (v) once large bubbles reach critical sizes they escape from the pool surface or are trapped in DED tracks. These mechanisms can guide the development of pore minimisation strategies.

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“…An In-situ multispectral photodetector has been used for porosity identification [14]. Adaptive vision-based detection of defects has been performed for DED in [15]. Residual stresses have been estimated applying a non-destructive post-processing using 3D digital image correlation (DIC) techniques in [16].…”

Section: Introductionmentioning

confidence: 99%

Residual stresses in thin walled-structures manufactured by directed energy deposition: In-situ measurements, fast thermo-mechanical simulation and buckling

Weisz-Patrault

Margerit

Constantinescu

2022

Additive Manufacturing

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Adaptive vision-based detection of laser-material interaction for directed energy deposition

Cited by 6 publications

References 40 publications

Advancements in 3D Printing: Directed Energy Deposition Techniques, Defect Analysis, and Quality Monitoring

Advancements in 3D Printing: Directed Energy Deposition Techniques, Defect Analysis, and Quality Monitoring

Pore evolution mechanisms during directed energy deposition additive manufacturing

Residual stresses in thin walled-structures manufactured by directed energy deposition: In-situ measurements, fast thermo-mechanical simulation and buckling

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