Utility of optical heterodyne displacement sensing and laser ultrasonics as in situ process control diagnostic for additive manufacturing

Manzo, Anthony J.; Helvajian, Henry

doi:10.1117/1.oe.57.4.041415

Cited by 8 publications

(9 citation statements)

References 51 publications

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“…The laser detection probe beam and laser source exciting the ultrasonic waves can be separated from the high temperature manufacturing process environment using optically transparent windows or other means. Laser ultrasonic techniques have been used to evaluate advanced manufacturing builds by using surface acoustic waves and bulk waves to detect surface and near subsurface defects ex situ [20][21][22][23] . Surface acoustic waves and bulk waves have also been used to evaluate material microstructure and grain size 24 , to infer the surface temperature in laserinduced thermal processes 22,25 , to predict internal temperature distributions based on waves propagating over multiple paths 26 , and to observe melting and solidi cation during crystal growth 27 .…”

Section: Introductionmentioning

confidence: 99%

“…Laser ultrasonic techniques have been used to evaluate advanced manufacturing builds by using surface acoustic waves and bulk waves to detect surface and near subsurface defects ex situ [20][21][22][23] . Surface acoustic waves and bulk waves have also been used to evaluate material microstructure and grain size 24 , to infer the surface temperature in laserinduced thermal processes 22,25 , to predict internal temperature distributions based on waves propagating over multiple paths 26 , and to observe melting and solidi cation during crystal growth 27 . Finally, laser ultrasonic methods have been used for high temperature measurements of materials properties 28 and for phase transformation studies in metals [29][30][31] .…”

Section: Introductionmentioning

confidence: 99%

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Real-Time Laser Ultrasonic Monitoring of Laser-Induced Thermal Processes

Morales

Harke

Tringe

et al. 2022

Preprint

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Intra- and inter-layer integrity of components fabricated with advanced manufacturing techniques, such as laser powder bed fusion, is dependent upon rapid heating, melting, and solidification processes. There is a need for new techniques to provide in situ feedback of these processes. Here a laser-based ultrasonic technique to probe thermal effects induced by a high-power continuous wave laser in titanium samples is described. Numerical simulations were performed to show that, for a spatially uniform heating beam, laser-induced surface acoustic waves are strongly influenced by surface heating conditions, are dispersive in the case of rapid heating, and that an abrupt velocity reduction happens upon the onset of surface melting. Furthermore, laser-based ultrasound experimental results which monitor the transient change of surface wave travel time associated with high power laser surface heating are provided. A pulsed laser is used to generate high frequency surface acoustic waves that propagate through the laser-heated region and are detected using a photorefractive crystal-based interferometer. Qualitative agreement is observed between theory and experiment with both showing a rapid delay in the surface wave velocity at the onset of illumination and further decrease in surface wave velocity associated with melting. It is demonstrated that changes in the surface wave velocity can be used to track local heating and detect the onset of surface melting in real time.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Real-Time Laser Ultrasonic Monitoring of Laser-Induced Thermal Processes

Morales

Harke

Tringe

et al. 2022

Preprint

View full text Add to dashboard Cite

show abstract

“…Laser ultrasonic techniques have been used to evaluate advanced manufacturing builds by using surface acoustic waves and bulk waves to detect surface and near subsurface defects ex situ 20 – 23 . Surface acoustic waves and bulk waves have also been used to evaluate material microstructure and grain size 24 , to infer the surface temperature in laser-induced thermal processes 22 , 25 , to predict internal temperature distributions based on waves propagating over multiple paths 26 , and to observe melting and solidification during crystal growth 27 . Finally, laser ultrasonic methods have been used for high temperature measurements of materials properties 28 and for phase transformation studies in metals 29 – 31 .…”

Section: Introductionmentioning

confidence: 99%

Real-time laser ultrasonic monitoring of laser-induced thermal processes

Morales

Harke

Tringe

et al. 2022

Sci Rep

View full text Add to dashboard Cite

Intra- and inter-layer integrity of components fabricated with advanced manufacturing techniques, such as laser powder bed fusion, is dependent upon rapid heating, melting, and solidification processes. There is a need for new techniques to provide in situ feedback of these processes. Here a laser-based ultrasonic technique to probe thermal effects induced by a high-power continuous wave laser in titanium samples is described. Numerical simulations were performed to show that, for a spatially uniform heating beam, laser-induced surface acoustic waves are strongly influenced by surface heating conditions, are dispersive in the case of rapid heating, and that an abrupt velocity reduction happens upon the onset of surface melting. Furthermore, laser-based ultrasound experimental results which monitor the transient change of surface wave travel time associated with high power laser surface heating are provided. A pulsed laser is used to generate high frequency surface acoustic waves that propagate through the laser-heated region and are detected using a photorefractive crystal-based interferometer. Qualitative agreement is observed between theory and experiment with both showing a rapid reduction in the surface wave velocity at the onset of illumination and further decrease in surface wave velocity associated with melting. It is demonstrated that changes in the surface wave velocity can be used to track local heating and detect the onset of surface melting in real time.

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“…Reviews covering previous AM monitoring research and further requirements for future systems have been published by Everton et al [11], Mani et al [12], and Grasso and Colosimo [13]. On-machine measurement solutions that have been developed include co-axial [10,[14][15][16][17][18][19][20][21][22][23][24][25] and off-axis [4][5][6][26][27][28][29][30] melt pool monitoring systems, as well as thermal [31][32][33] and optical [23,[34][35][36][37] imaging of the powder bed. The target of these in-process monitoring systems is to detect defective regions of the powder bed, to inform the user that the component being built may require either corrective action or termination.…”

Section: Introductionmentioning

confidence: 99%

Multi-view fringe projection system for surface topography measurement during metal powder bed fusion

Dickins¹,

Widjanarko²,

Sims-Waterhouse³

et al. 2020

J. Opt. Soc. Am. A

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Metal powder bed fusion (PBF) methods need in-process measurement methods to increase user confidence and encourage further adoption in high-value manufacturing sectors. In this paper, a novel measurement method for PBF systems is proposed that uses multi-view fringe projection to acquire high-resolution surface topography information of the powder bed. Measurements were made using a mock-up of a commercial PBF system to assess the system's accuracy and precision in comparison to conventional single-view fringe projection techniques for the same application. Results show that the multi-view system is more accurate, but less precise, than single-view fringe projection on a point-by-point basis. The multi-view system also achieves a high degree of surface coverage by using alternate views to access areas not measured by a single camera.

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Utility of optical heterodyne displacement sensing and laser ultrasonics as in situ process control diagnostic for additive manufacturing

Cited by 8 publications

References 51 publications

Real-Time Laser Ultrasonic Monitoring of Laser-Induced Thermal Processes

Real-Time Laser Ultrasonic Monitoring of Laser-Induced Thermal Processes

Real-time laser ultrasonic monitoring of laser-induced thermal processes

Multi-view fringe projection system for surface topography measurement during metal powder bed fusion

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