High-Fidelity Optical Monitoring of Laser Powder Bed Fusion via Aperture Division Multiplexing
Fuente:
arXiv
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| Autori principali: | , , |
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| Natura: | Preprint |
| Pubblicazione: |
2024
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| _version_ | 1866912128489750528 |
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| author | Penny, Ryan W. Kutschke, Zachery Hart, A. John |
| author_facet | Penny, Ryan W. Kutschke, Zachery Hart, A. John |
| contents | Qualification of high-performance metal components produced by laser powder bed fusion (LPBF) must identify process-induced porous defects that reduce ductility and nucleate fatigue cracking. Detecting such defects via optical monitoring of LPBF provides a path towards in-process quality control without downstream testing such as by computed tomography. However, integration of in-process sensing with LPBF is hampered by geometric and optical complications and, as a result, it has yet to be proven that the finest pores that limit component fatigue life can be resolved via in situ data. We present aperture division multiplexing (ADM) as a method for simultaneously focusing the process laser and providing unobstructed optical access for high-fidelity process monitoring using a common optic. Construction of an ADM optic of achieving imaging at 50 micron spatial resolution in the mid-wave infrared is described, and this optic is demonstrated on a production-representative LPBF testbed. High-speed infrared video data are correlated to micro-CT measurement of pores as fine as 4.3 microns, through multiple process signatures, establishing the promise of ADM for qualification of LPBF component fatigue performance. |
| format | Preprint |
| id |
arxiv_https___arxiv_org_abs_2411_13703 |
| institution | arXiv |
| publishDate | 2024 |
| record_format | arxiv |
| spellingShingle | High-Fidelity Optical Monitoring of Laser Powder Bed Fusion via Aperture Division Multiplexing Penny, Ryan W. Kutschke, Zachery Hart, A. John Optics Qualification of high-performance metal components produced by laser powder bed fusion (LPBF) must identify process-induced porous defects that reduce ductility and nucleate fatigue cracking. Detecting such defects via optical monitoring of LPBF provides a path towards in-process quality control without downstream testing such as by computed tomography. However, integration of in-process sensing with LPBF is hampered by geometric and optical complications and, as a result, it has yet to be proven that the finest pores that limit component fatigue life can be resolved via in situ data. We present aperture division multiplexing (ADM) as a method for simultaneously focusing the process laser and providing unobstructed optical access for high-fidelity process monitoring using a common optic. Construction of an ADM optic of achieving imaging at 50 micron spatial resolution in the mid-wave infrared is described, and this optic is demonstrated on a production-representative LPBF testbed. High-speed infrared video data are correlated to micro-CT measurement of pores as fine as 4.3 microns, through multiple process signatures, establishing the promise of ADM for qualification of LPBF component fatigue performance. |
| title | High-Fidelity Optical Monitoring of Laser Powder Bed Fusion via Aperture Division Multiplexing |
| topic | Optics |
| url | https://arxiv.org/abs/2411.13703 |