In situ monitoring of direct laser metal deposition of a nickel-based superalloy using infrared thermography

Mazzarisi, Marco; Campanelli, Sabina Luisa; Angelastro, Andrea; Palano, F.; Dassisti, Michele

doi:10.1007/s00170-020-06344-0

Cited by 24 publications

(7 citation statements)

References 39 publications

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“…The value represents the energy (related to the laser beam) provided to the deposition point in order to create the track, but also wasted to heat up other elements involved in this phase of the process, i.e., the powder dispersed in the glovebox, the substrate, and the argon that is dropped out by the suction system. Temperatures were measured by means of the pyrometer but a reference was made to [69] to approximate the overheating of the substrate and to quantify the energy lost during the deposition.…”

Section: Exergetic Analysis: Results and Discussionmentioning

confidence: 99%

A monitoring framework based on exergetic analysis for sustainability assessment of direct laser metal deposition process

Selicati

Mazzarisi

Lovecchio

et al. 2021

Int J Adv Manuf Technol

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With the constant increase of energy costs and environmental impacts, improving the process efficiency is considered a priority issue for the manufacturing field. A wide knowledge about materials, energy, machinery, and auxiliary equipment is required in order to optimize the overall performance of manufacturing processes. Sustainability needs to be assessed in order to find an optimal compromise between technical quality of products and environmental compatibility of processes. In this new Industry 4.0 era, innovative manufacturing technologies, as the additive manufacturing, are taking a predominant role. The aim of this work is to give an insight into how thermodynamic laws contribute at the same time to improve energy efficiency of manufacturing resources and to provide a methodological support to move towards a smart and sustainable additive process. In this context, a fundamental step is the proper design of a sensing and real-time monitoring framework of an additive manufacturing process. This framework should be based on an accurate modelling of the physical phenomena and technological aspects of the considered process, taking into account all the sustainability requirements. To this end, a thermodynamic model for the direct laser metal deposition (DLMD) process was proposed as a test case. Finally, an exergetic analysis was conducted on a prototype DLMD system to validate the effectiveness of an ad-hoc monitoring system and highlight the limitations of this process. What emerged is that the proposed framework provided significant advantages, since it represents a valuable approach for finding suitable process management strategies to identify sustainable solutions for innovative manufacturing procedures.

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Section: Exergetic Analysis: Results and Discussionmentioning

confidence: 99%

A monitoring framework based on exergetic analysis for sustainability assessment of direct laser metal deposition process

Selicati

Mazzarisi

Lovecchio

et al. 2021

Int J Adv Manuf Technol

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“…The welding sample is a rod with a diameter of 20 mm and a length of 40 mm. Generally, the weld bead during FRW emits infrared energy [36]. In this study, Ultimaker Cura software was utilized to generate the 3D printing program.…”

Section: Methodsmentioning

confidence: 99%

Weld Strength of Friction Welding of Dissimilar Polymer Rods Fabricated by Fused Deposition Modeling

Kuo

Lee

2022

Polymers

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Friction welding (FRW) is a promising method for joining cylindrical components of dissimilar and similar polymers or metals. In particular, FRW is capable of generating defect-free welds. Fused deposition modeling (FDM) has been widely employed in the automotive industry, ranging from lightweight tools, testing models, and functional parts. Conventionally, dissimilar parts fabricated by FDM are joined by glue. However, distinct disadvantages of this approach include both low joining strength and low joining efficiency. Hitherto, little has been reported on the characterizations of weld strength of FRW of dissimilar parts fabricated by FDM. In addition, FRW of dissimilar polymeric materials is a difficult task because different polymers have different physical, rheological, and mechanical properties. In this study, the effects of welding revolution on the weld strength of friction welding dissimilar parts fabricated by FDM are investigated experimentally. It was found that the average flexural strength of dissimilar polymer rods fabricated by FRW is about 1.52 times that of dissimilar polymer rods fabricated by gluing. The highest flexure strength can be obtained by FRW using polylactic acid (PLA) and PC (polycarbonate) rods. The average impact strength of dissimilar polymer rods fabricated by FRW is about 1.04 times that of dissimilar polymer rods joined by gluing. The highest impact strength can be obtained by FRW using PLA to PLA rods.

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“…Hence, values of physical properties of the AISI 304 stainless steel at 1000 °C, as listed in Table 8, were used in the model. Of fundamental importance are the temperature values of the process, which were compared with the results obtained from previous experimental tests carried out with the same metal alloy using an IR thermal camera [49].…”

Section: Effects On the Clad Widthmentioning

confidence: 99%

Influence of standoff distance and laser defocusing distance on direct laser metal deposition of a nickel-based superalloy

Mazzarisi

Errico

Angelastro

et al. 2022

Int J Adv Manuf Technol

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The direct laser metal deposition (DLMD) is an additive manufacturing technology, based on laser cladding, which focuses mainly on 3D manufacturing applications. DLMD allows the production of thin-walled components by overlaying single-track depositions. Several issues can affect the deposition process and compromise the flatness of the surface on which subsequent tracks will be deposited. This work focused on deposition troubles simulated by means of a designed variation of the standoff distance and the laser defocusing distance. The effects of these two important process parameters on the deposition process were investigated. The experimental tests were performed by depositing a nickel-based superalloy powder on AISI 304 stainless steel plates through a coaxial nozzle. The work was carried out using an ytterbium fiber laser source and a deposition head equipped with an advanced and innovative motorized optics system. This allows the decoupled variation of the laser defocusing distance and consequently the laser spot size on the substrate surface with respect to the standoff distance. Results showed an influence of standoff distance and laser defocusing distance on the geometrical characteristics of the clad, such as clad width, clad height, penetration depth, and dilution. An experimental setup consisting of a light coaxial to the powder flow and a laterally positioned camera was designed to investigate the spatial powder distribution. Moreover, an analytical model for the powder distribution and clad width were proposed and validated. The analysis of variance (ANOVA) with a general linear model was also employed to describe the results.

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In situ monitoring of direct laser metal deposition of a nickel-based superalloy using infrared thermography

Cited by 24 publications

References 39 publications

A monitoring framework based on exergetic analysis for sustainability assessment of direct laser metal deposition process

A monitoring framework based on exergetic analysis for sustainability assessment of direct laser metal deposition process

Weld Strength of Friction Welding of Dissimilar Polymer Rods Fabricated by Fused Deposition Modeling

Influence of standoff distance and laser defocusing distance on direct laser metal deposition of a nickel-based superalloy

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