Optical monitoring of high power direct diode laser cladding

Liu, Shuang; Farahmand, Parisa; Kovacevic, Radovan

doi:10.1016/j.optlastec.2014.06.002

Cited by 62 publications

(17 citation statements)

References 17 publications

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“…In addition, the surface of the cladded track showed that for a lower laser power, the amount of powder not caught by molten pool increased and resulted in unmelted powder sticking to the hot surface of cladded track. The same observation was reported by Liu et al [20] in laser cladding with high power direct diode laser. This might be attributed to the fact that with lower level of laser power, the amount of input energy was not high enough to melt all of injected powder.…”

Section: The Effect Of Process Parameters On Microhardness Based On Rsmsupporting

confidence: 85%

Parametric Study and Multi-Criteria Optimization in Laser Cladding by a High Power Direct Diode Laser

Farahmand

Kovacevic

2014

Lasers Manuf. Mater. Process.

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In laser cladding, the performance of the deposited layers subjected to severe working conditions (e.g., wear and high temperature conditions) depends on the mechanical properties, the metallurgical bond to the substrate, and the percentage of dilution. The clad geometry and mechanical characteristics of the deposited layer are influenced greatly by the type of laser used as a heat source and process parameters used. Nowadays, the quality of fabricated coating by laser cladding and the efficiency of this process has improved thanks to the development of high-power diode lasers, with power up to 10 kW. In this study, the laser cladding by a high power direct diode laser (HPDDL) as a new heat source in laser cladding was investigated in detail. The high alloy tool steel material (AISI H13) as feedstock was deposited on mild steel (ASTM A36) by a HPDDL up to 8kW laser and with new design lateral feeding nozzle. The influences of the main process parameters (laser power, powder flow rate, and scanning speed) on the clad-bead geometry (specifically layer height and depth of the heat affected zone), and clad microhardness were studied. Multiple regression analysis was used to develop the analytical models for desired output properties according to input process parameters. The Analysis of Variance was applied to check the accuracy of the developed models. The response surface methodology (RSM) and desirability function were used for multi-criteria optimization of the cladding process. In order to investigate the effect of process parameters on the molten pool evolution, in-situ monitoring was utilized. Finally, the validation results for optimized process conditions show the predicted results were in a good agreement with measured values. The multicriteria optimization makes it possible to acquire an efficient process for a combination of clad geometrical and mechanical characteristics control.Keywords Laser cladding . High power direct diode laser . Response surface methodology (RSM) . Multi-response optimization Lasers Manuf. Mater. Process.

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Section: The Effect Of Process Parameters On Microhardness Based On Rsmsupporting

confidence: 85%

Parametric Study and Multi-Criteria Optimization in Laser Cladding by a High Power Direct Diode Laser

Farahmand

Kovacevic

2014

Lasers Manuf. Mater. Process.

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“…The brightness gradient at the top of the molten pool is steep due to intense heat dissipation through the substrate. The high brightness regions on both sides of the melt pool could be a consequence of the high emissivity, proper of the non-molten particles, and oxides [ 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 ]. Similar considerations were made by Doubenskaia et al [ 29 ], who considered the high thermal emission in the peripheral area of the melt pool due to oxides and other non-metallic inclusions that are usually concentrated in that region.…”

Section: Methodsmentioning

confidence: 99%

Coaxial Monitoring of AISI 316L Thin Walls Fabricated by Direct Metal Laser Deposition

et al. 2021

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Direct metal laser deposition (DMLD) is an additive manufacturing technique suitable for coating and repair, which has been gaining a growing interest in 3D manufacturing applications in recent years. However, its diffusion in the manufacturing industry is still limited due to technical challenges to be solved—both the sub-optimal quality of the final parts and the low repeatability of the process make the DMLD inadequate for high-value applications requiring high-performance standards. Thus, real-time monitoring and process control are indispensable requirements for improving the DMLD process. The aim of this study was the optimization of deposition strategies for the fabrication of thin walls in AISI 316L stainless steel. For this purpose, a coaxial monitoring system and image processing algorithms were employed to study the melt pool geometry. The comparison tests carried out highlighted how the region-based active contour algorithm used for image processing is more efficient and stable than others covered in the literature. The results allowed the identification of the best deposition strategy. Therefore, it is shown how this monitoring methodology proved to be suitable for designing and implementing the right building strategy for DMLD manufactured 3D components. A fast and stable image processing method was achieved, which can be considered for future closed-loop monitoring in real-time applications.

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“…Smurov et al 47 comprehensively analyzed deposition by monochromatic pyrometer, multiwavelength pyrometer, and IR camera, and presented a fusion method of diverse temperature data. In the research conducted by Liu et al, 48 the variation of the molten pool temperature was measured by a pyrometer; temperature distribution, molten pool size, and cooling rate were studied by an IR camera.…”

Section: Temperature Signature Monitoringmentioning

confidence: 99%

Review on adaptive control of laser-directed energy deposition

et al. 2020

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Laser directed energy deposition (LDED) is one of the most important parts of metal additive manufacturing, which can provide fast building speed, allows for large building volumes, and is suitable for part repair. LDED can manufacture components layer by layer through processes of rapid heating, melting, solidification, and cooling with the laser beam as a heat source. However, deposition quality and repeatability of components produced by LDED are poor because of the complex thermal cycle and processing environment, hindering the spread of this technique. Adaptive control technology (ACT) is consistently considered an effective and potential way to solve the problem. Many studies have focused on LDED and established the relations of process parameters, process signatures, and product qualities, which promote the rapid development of ACT, with the development of monitoring devices and data processing technology. We review and discuss the problems existing in the ACT of LDED.

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Optical monitoring of high power direct diode laser cladding

Cited by 62 publications

References 17 publications

Parametric Study and Multi-Criteria Optimization in Laser Cladding by a High Power Direct Diode Laser

Parametric Study and Multi-Criteria Optimization in Laser Cladding by a High Power Direct Diode Laser

Coaxial Monitoring of AISI 316L Thin Walls Fabricated by Direct Metal Laser Deposition

Review on adaptive control of laser-directed energy deposition

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