TY - JOUR
T1 - Melt pool width measurement in a multi-track, multi-layer laser powder bed fusion print using single-camera two-wavelength imaging pyrometry
AU - Vallabh, Chaitanya Krishna Prasad
AU - Zhang, Haolin
AU - Anderson, David Scott
AU - To, Albert C.
AU - Zhao, Xiayun
N1 - Publisher Copyright:
© The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature 2024.
PY - 2024/5
Y1 - 2024/5
N2 - In laser powder bed fusion (LPBF) additive manufacturing, melt pool characterization is one of the potential approaches toward rapid process qualification and efficient non-destructive evaluation of printed parts. Especially melt pool width measurement is crucial for understanding the print process regimes, estimating the solidified melt pool depth, and identifying any process anomalies, among other attributes of interest. While existing works focus on monitoring melt pools of single scan tracks or single layer prints, melt pool characterization for a multi-track multi-layer (MTML) LPBF print has not been extensively studied. In this work, we employ our lab-designed coaxial single-camera two-wavelength imaging pyrometry (STWIP) system to monitor in-situ melt pool properties during a MTML LPBF process. The STWIP-measured melt pool widths are validated using a serial sectioning machine (Robo-Met, UES). The in-situ STWIP and ex-situ Robo-Met measurement data are in close agreement with each other, having a mean absolute error and root mean squared error of 9.83 μm and 16.53 μm, respectively. Furthermore, we demonstrate the successful mapping of melt pool location and melt pool size on the printed MTML part. In sum, this work demonstrates the capability and the applicability of STWIP for accurate large-scale melt pool monitoring during LPBF processing of practical parts, thereby facilitating the development of LPBF process models and control strategies.
AB - In laser powder bed fusion (LPBF) additive manufacturing, melt pool characterization is one of the potential approaches toward rapid process qualification and efficient non-destructive evaluation of printed parts. Especially melt pool width measurement is crucial for understanding the print process regimes, estimating the solidified melt pool depth, and identifying any process anomalies, among other attributes of interest. While existing works focus on monitoring melt pools of single scan tracks or single layer prints, melt pool characterization for a multi-track multi-layer (MTML) LPBF print has not been extensively studied. In this work, we employ our lab-designed coaxial single-camera two-wavelength imaging pyrometry (STWIP) system to monitor in-situ melt pool properties during a MTML LPBF process. The STWIP-measured melt pool widths are validated using a serial sectioning machine (Robo-Met, UES). The in-situ STWIP and ex-situ Robo-Met measurement data are in close agreement with each other, having a mean absolute error and root mean squared error of 9.83 μm and 16.53 μm, respectively. Furthermore, we demonstrate the successful mapping of melt pool location and melt pool size on the printed MTML part. In sum, this work demonstrates the capability and the applicability of STWIP for accurate large-scale melt pool monitoring during LPBF processing of practical parts, thereby facilitating the development of LPBF process models and control strategies.
KW - Additive manufacturing
KW - Imaging pyrometry
KW - Melt pool
KW - Multi-layer print
KW - Powder bed fusion
UR - http://www.scopus.com/inward/record.url?scp=85189200372&partnerID=8YFLogxK
UR - http://www.scopus.com/inward/citedby.url?scp=85189200372&partnerID=8YFLogxK
U2 - 10.1007/s00170-024-13486-y
DO - 10.1007/s00170-024-13486-y
M3 - Article
AN - SCOPUS:85189200372
SN - 0268-3768
VL - 132
SP - 2575
EP - 2585
JO - International Journal of Advanced Manufacturing Technology
JF - International Journal of Advanced Manufacturing Technology
IS - 5-6
ER -