Part defects identification in selective laser melting via digital image processing of powder bed anomalies

Abstract

Despite the potential of additive manufacturing and specifically of selective laser melting, several considerable barriers exist to widespread utilization, especially in specific industries that produce high-value components. Quality control and mechanical characterization remain the most expensive challenge. The quality and mechanical properties of the manufactured parts are influenced by potential defects; the characteristics of these defects, such as size, shape, location, and distribution, have shown to play key roles in mechanical properties. This work proposes a methodology for providing the identification of powder bed anomalies and consequent part defects through a synchronized analysis of the powder layers via digital image processing. This method can be used to study the critical defects formation during the layerwise process, providing important information about their location without the use of expensive or destructive measurements.

Online Monitoring Technology of Metal Powder Bed Fusion Processes: A Review

“…Moreover, the method successfully realizes manual closed–loop control and full feedback control. Boschetto et al [ 30 ] proposed the use of digital image processing to monitor the defects of powder beds during SLM. In this study, thousands of images of powder beds taken by CCD cameras were analyzed using 2D and 3D analysis to identify single−layer defects and defects between powder beds, respectively.…”