In-Process Control for L-PBF

Abstract

In this program an in-process inspection methodology for laser powder bed fusion (LPBF) was developed using surface height measurements of the melt layer. A full bed optical profilometer was developed capable of capturing almost 100 MM measurements of each layer with high precision. This data was processed through a Flaw detection algorithm and evaluated using about 100 coupons made with approximately 10,000 seeded flaws. The effects of flaw type, flaw severity and flaw size were evaluated using in-process inspection validated using micro-CT. A closed loop control scheme was developed and tested where detected Flaw maps were read by the Printer and layer repairs were made automatically for every Build layer, without Operator intervention. Results are presented and discussed.

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Document Details

Document Type
Technical Report
Publication Date
Dec 05, 2021
Accession Number
AD1154277

Entities

People

  • David Maass

Tags

Communities of Interest

  • Energy and Power Technologies

DTIC Thesaurus Topics

  • Accuracy
  • Additive Manufacturing
  • Algorithms
  • Boundaries
  • Computer Programming
  • Data Processing
  • Detection
  • Detectors
  • Diameters
  • Fabrication
  • Geometry
  • Graphical User Interface
  • High Reliability
  • Image Processing
  • Inspection
  • Machining
  • Manufacturing
  • Materials
  • Measurement
  • Mechanical Engineering
  • Operating Systems
  • Standards
  • Surface Finishing
  • Surface Roughness
  • Three Dimensional
  • X-Ray Computed Tomography

Readers

  • Manufacturing Engineering.
  • Reinforced Composite Materials

Technology Areas

  • Directed Energy