TY - JOUR
T1 - A systematic study and framework of fringe projection profilometry with improved measurement performance for in-situ LPBF process monitoring
AU - Zhang, Haolin
AU - Vallabh, Chaitanya Krishna Prasad
AU - Xiong, Yubo
AU - Zhao, Xiayun
N1 - Publisher Copyright:
© 2022 Elsevier Ltd
PY - 2022/3/15
Y1 - 2022/3/15
N2 - Fringe Projection Profilometry (FPP) is a cost-effective and non-invasive technology that has been shown to measure finer features. In this work, we developed an in-situ FPP method to measure the dynamic topography of powder bed and printed layer during Laser Powder Bed Fusion (LPBF) additive manufacturing (AM) process. A systematic study towards developing a comprehensive framework of LPBF-specific FPP is demonstrated to enhance and evaluate the performance of applying FPP for in-situ LPBF monitoring, including 1) a modified sensor model with localized correction; 2) improved phase unwrapping with FFT filtering 3) quantitative uncertainty analysis; and 4) experimental validation with ex-situ characterization. The developed LPBF-specific FPP system and methods are implemented on a commercial LPBF-AM machine, achieving better accuracy, more robustness, and increased field of view while maintaining sufficient measurement range and decent resolution, in contrast to literature methods. The established FPP framework will facilitate the development of closed-loop control strategies for advancing LPBF based AM.
AB - Fringe Projection Profilometry (FPP) is a cost-effective and non-invasive technology that has been shown to measure finer features. In this work, we developed an in-situ FPP method to measure the dynamic topography of powder bed and printed layer during Laser Powder Bed Fusion (LPBF) additive manufacturing (AM) process. A systematic study towards developing a comprehensive framework of LPBF-specific FPP is demonstrated to enhance and evaluate the performance of applying FPP for in-situ LPBF monitoring, including 1) a modified sensor model with localized correction; 2) improved phase unwrapping with FFT filtering 3) quantitative uncertainty analysis; and 4) experimental validation with ex-situ characterization. The developed LPBF-specific FPP system and methods are implemented on a commercial LPBF-AM machine, achieving better accuracy, more robustness, and increased field of view while maintaining sufficient measurement range and decent resolution, in contrast to literature methods. The established FPP framework will facilitate the development of closed-loop control strategies for advancing LPBF based AM.
KW - Additive Manufacturing
KW - Fringe Projection
KW - In-situ Monitoring
KW - Powder Bed Fusion
KW - Sensor Model
KW - Uncertainty Analysis
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U2 - 10.1016/j.measurement.2022.110796
DO - 10.1016/j.measurement.2022.110796
M3 - Article
AN - SCOPUS:85123764389
SN - 0263-2241
VL - 191
JO - Measurement: Journal of the International Measurement Confederation
JF - Measurement: Journal of the International Measurement Confederation
M1 - 110796
ER -