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Qualify a NIR camera to detect thermal deviation during aluminum WAAM

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Abstract

This paper proposes to qualify the minimal quality deviation that can be detected by a near-infrared camera during aluminum wire arc additive manufacturing. First, a review of the literature is done to highlight the interest in monitoring the melt pool in industrial condition for thermal management during manufacturing. It points out the relevance of the use of a near-infrared camera for steels, but it has to be demonstrated for aluminum alloys. Indeed, the melt pool of the aluminum is significantly dimmer and less distinct than the melt pool of the steels. An experimental design is proposed to qualify the minimal quality deviation that can be detected on a thin wall. The chosen default to correlate with the thermal deviation is the width of the wall. A method is proposed to extract a thermal metric from the camera image and to analyze its sensitivity to a width deviation of the wall. The paper shows the correlation between the width of the wall and the thermal metric for different heat conditions. Moreover, the thermal metric is sensitive to width deviation either on the wall scale or on the bead scale. It indicates the relevance of a near-infrared camera to detect heat accumulation-induced width deviation during wire arc additive manufacturing of aluminum alloy.

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Acknowledgements

This work made use of the facilities of the platform S.mart Grenoble Alpes. The authors thank the staff of S.mart Grenoble Alpes, especially Devos Camille and Duong Quoc-Bao for their help on 0-V detection.

Funding

This work benefited from the support of the project METALICANR-21-CE10-0003 of the French National Research Agency (ANR).

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Authors and Affiliations

  1. Institute of Engineering, Univ. Grenoble Alpes, Grenoble INP*, CNRS, G-SCOP, 38000, Grenoble, France

    Anthony Dellarre, Nicolas Béraud, Frédéric Vignat, François Villeneuve & Maxime Limousin

  2. Lamcos, INSA Lyon, Université de Lyon, CNRS, Villeurbanne, France

    Nicolas Tardif

Authors
  1. Anthony Dellarre
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  2. Nicolas Béraud
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  3. Nicolas Tardif
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  4. Frédéric Vignat
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  5. François Villeneuve
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  6. Maxime Limousin
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Anthony Dellarre and Nicolas Béraud. The first draft of the manuscript was written by Anthony Dellarre, and all authors commented on previous versions of the manuscript. All authors read and approved the final version of the manuscript.

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Correspondence to Anthony Dellarre.

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Dellarre, A., Béraud, N., Tardif, N. et al. Qualify a NIR camera to detect thermal deviation during aluminum WAAM. Int J Adv Manuf Technol 127, 625–634 (2023). https://doi.org/10.1007/s00170-023-11587-8

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  • DOI: https://doi.org/10.1007/s00170-023-11587-8

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