In-process sensing in selective laser melting (SLM) additive manufacturing
By Thomas Spears, S. Gold. Integrating Materials and Manufacturing Innovation, 2016
464 citations recorded by the source corpus.
Additive manufacturing and specifically metal selective laser melting (SLM) processes are rapidly being industrialized. In order for this technology to see more widespread use as a production modality, especially in heavily regulated industries such as aerospace and medical device manufacturing, there is a need for robust process monitoring and control capabilities to be developed that reduce process variation and ensure quality. The current state of the art of such process monitoring technology is reviewed in this paper. The SLM process itself presents significant challenges as over 50 different process input variables impact the characteristics of the finished part. Understanding the impact of feed powder characteristics remains a challenge. Though many powder characterization techniques have been developed, there is a need for standardization of methods most relevant to additive manufacturing. In-process sensing technologies have primarily focused on monitoring melt pool signatures, either from a Lagrangian reference frame that follows the focal point of the laser or from a fixed Eulerian reference frame. Correlations between process measurements, process parameter settings, and quality metrics to date have been primarily qualitative. Some simple, first-generation process control strategies have also been demonstrated based on these measures. There remains a need for connecting process measurements to process models to enable robust model-based control.
Subfields: Automotive Engineering, Mechanical Engineering
View Paper: https://www.semanticscholar.org/paper/603a2902a912bf24a5192dee6d7a00d5bf4a7fed
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Citations in the corpus
- In-situ measurement and monitoring methods for metal powder bed fusion: an updated review (2021, unknown): “This study focuses on laser and electron beam PBF processes (L-PBF and EB-PBF respectively) only (an overview of the PBF process can be found in Gibson et al (2014), King et al (2015), Körner (2016), Spears and Gold (2016), Popov et al (2021), Sing et al (2021).”
- The barriers to the progression of additive manufacture: perspectives from UK industry (2018, background): “The long-term requirements of industry and aims of research are to create a closed-loop system (Spears and Gold, 2016), where the process parameters are controlled by the feedback, thus allowing for in-build compensation of fluctuations as they occur.”
- Process defects and in situ monitoring methods in metal powder bed fusion: a review (2017, unknown): “…Ferrar et al., 2012; Spears and Gold, 2016 Li et al., 2012 Edwards et al., 2013; Chlebus et al., 2011; Buchbinder et al., 2014; Kempen et al., 2013 Spears and Gold, 2016 Powder handling & deposition system Foster et al., 2015 Foster et al., 2015; Kleszczynski et al., 2012 Foster et al., 2015;…”
- Additive Manufacturing: A Comprehensive Review (2024, background): “SLM is also widely used with cobalt-chromium, titanium alloys, nickel alloys, iron-based alloys, aluminum alloys, niobium alloys, refractory alloys, amorphous alloys, and super alloys [72].”
- Fatigue of additive manufactured Ti-6Al-4V, Part I: The effects of powder feedstock, manufacturing, and post-process conditions on the resulting microstructure and defects (2020, background): “Researchers have implemented pyrometers, photodiodes, high-speed cameras, or a combination of these instruments to investigate several melt pool or AM related properties [112,113].”
- In-Situ Defect Detection in Laser Powder Bed Fusion by Using Thermography and Optical Tomography—Comparison to Computed Tomography (2020, background): “Therefore, several different in-situ monitoring approaches have been developed to observe distinct process parameters and objects such as laser power [17,18], powder recoating and powder bed surface [19], powder bed compaction [20], plume and spatter behavior [21,22], particle gas emissions [23] or ”