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ANALYZING REMELTING CONDITIONS BASED ON IN-SITU MELT POOL DATA FUSION FOR OVERHANG BUILDING IN POWDER BED FUSION PROCESS

Published

Author(s)

Yan Lu, Brandon Lane, Zhuo Yang, Jaehyuk Kim, Yande Ndiaye

Abstract

Coaxial melt pool monitoring (MPM) images provide in-depth insights into the building process of laser powder bed fusion additive manufacturing. An in-situ MPM image captures the independent melting condition at a specific scanning position. However, it is challenging to identify material defects such as horizontal lack-of-fusion using individual, discontinuous MPM images. This paper builds upon the authors' previous work on data registration and data fusion, to analyze material remelting conditions based on melt pool images. MPM data are fused to formulate layerwise remelting maps to evaluate printing quality. A 3D part with various overhang features was built to verify the method. A regular layer with solid support from the previous layers has around 30% remelting ratio for the given laser scan conditions. In contrast, overhang regions remelted at about 10% with the same process setting, which are too narrow to provide sufficient material fusion, resulting in lack-of-fusion between melting tracks. The negative impact in remelting would not immediately disappear in subsequent layers following the overhang regions. Results shows three additional layers are required to fully recover the remelting condition back to normal. The remelting results from MPM are also visible within layerwise optical images of the same surface.
Proceedings Title
Proc. of Solid Freeform Fabrication Symposium 2021
Conference Dates
August 2-4, 2021
Conference Location
Austin, TX, US
Conference Title
Solid Freeform Fabrication Symposium 2021

Keywords

additive manufacturing, data fusion, in-process monitoring

Citation

Lu, Y. , Lane, B. , Yang, Z. , Kim, J. and Ndiaye, Y. (2021), ANALYZING REMELTING CONDITIONS BASED ON IN-SITU MELT POOL DATA FUSION FOR OVERHANG BUILDING IN POWDER BED FUSION PROCESS, Proc. of Solid Freeform Fabrication Symposium 2021, Austin, TX, US, [online], https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=933025 (Accessed May 27, 2023)
Created November 1, 2021, Updated November 29, 2022