HIGH-PRECISION MEASUREMENT OF MELT POOL PROPERTIES DURING LASER-BASED POWDER BED FUSION OF METALS BY HIGH-SPEED IMAGING

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Date

2023

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University of Texas at Austin

Abstract

Laser-based powder bed fusion of metals is used to produce complex and high-performance components for different industrial applications. Due to the high complexity of the underlying physical mechanisms during the process, its control is still challenging. To avoid the formation of defects, which affect mechanical properties, a huge amount of specific know-how is crucial. Especially for regulated industries, such as medical or aerospace, this is a limiting factor for the widespread usage. In this work, high-speed imaging in combination with a high-magnification optic is used to gain deeper insight into the property-determining mechanisms and boundary conditions during the process. Thereby, the intensity distribution from the melt pool radiation is measured and analyzed with an imaging script to determine width, length, and cooling rate with a resolution of 1.44 µm/pixel. The potential of this data for predicting resulting scan track properties is demonstrated. It can be shown that an automatic width measurement deviates from the manually measured value by only 1.2% and the length measurement by 1.4%. It is also possible to detect anomalies in the process, such as balling effects.

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