Abstract
One of the most significant barriers to the broad adoption of additive manufacturing (AM) is the qualification of AM produced parts. With the high market competition, quality has become the market differentiator for products and services. To maintain or enhance the quality of the products, manufacturers use two techniques, quality assurance and control. In fact, many researchers characterize the quality assurance and control as the biggest challenge to widespread adoption of AM technologies for metals parts in aerospace industries. One approach to overcome this challenge is to implement in-situ process monitoring and inspection systems to enhance the quality of the printed parts and AM processes. This has been highlighted by numerous research efforts for the past decade and continues to be identified as a high priority research in the AM processes. In this paper, we review current process monitoring and control systems for metal AM in Powder Bed Fusion and Directed Energy Deposition systems. And then, possible inspection system configurations for improving the quality of AM printed parts are discussed based on the proposed framework and requirement. A comprehensive real-time inspection method and a closed loop monitoring system are proposed to address the quality control for metal-based AM processes
Similar content being viewed by others
References
Moon, S. K., Tan, Y. E., Hwang, J., and Yoon, Y.-J., “Application of 3D Printing Technology for Designing Light-Weight Unmanned Aerial Vehicle Wing Structures,” Int. J. Precis. Eng. Manuf.-Green Tech., Vol. 1, No. 3, pp. 223–228, 2014.
Frazier, W. E., “Metal Additive Manufacturing: A Review,” Journal of Materials Engineering and Performance, Vol. 23, No. 6, pp. 1917–1928, 2014.
Yao, X., Moon, S. K., and Bi, G., “A Cost-Driven Design Methodology for Additive Manufactured Variable Platforms in Product Families,” Journal of Mechanical Design, Vol. 138, No. 4, Paper No. 041701, 2016.
Ko, H., Moon, S. K., and Hwang, J., “Design for Additive Manufacturing in Customized Products,” Int. J. Precis. Eng. Manuf., Vol. 16, No. 11, pp. 2369–2375, 2015.
Cannavan, A., Kay, J. F., and Le Bizec, B., “Quality Assurance and Quality Control,” in: Chemical Analysis of Antibiotic Residues in Food, Wang, J., Mac Neil, J. D., and Kay, J. F., (Eds.), John Wiley & Sons, pp. 327–345, 2011.
Mani, M., Lane, B., Donmez, A., Feng, S., Moylan, S., et al., “Measurement Science Needs for Real-Time Control of Additive Manufacturing Powder Bed Fusion Processes,” National Institute of Standards and Technology, Gaithersburg, MD, Standard No. NISTIR, Vol. 8036, 2015.
Standard, A., “Standard Terminology for Additive Manufacturing Technologies,” ASTM International F2792-12a, 2012.
Petrat, T., Graf, B., Gumenyuk, A., and Rethmeier, M., “Laser Metal Deposition as Repair Technology for a Gas Turbine Burner Made of Inconel 718,” Physics Procedia, Vol. 83, pp. 761–768, 2016.
Król, M., Dobrzanski, L., and Reimann, I. C., “Surface Quality in Selective Laser Melting of Metal Powders,” Archives of Materials Science and Engineering, Vol. 60, No. 2, pp. 87–92, 2013.
Ding, Y., Warton, J., and Kovacevic, R., “Development of Sensing and Control System for Robotized Laser-Based Direct Metal Addition System,” Additive Manufacturing, Vol. 10, pp. 24–35, 2016.
Yadroitsev, I., Bertrand, P., and Smurov, I., “Parametric Analysis of the Selective Laser Melting Process,” Applied Surface Science, Vol. 253, No. 19, pp. 8064–8069, 2007.
Sun, J., Yang, Y., and Wang, D., “Parametric Optimization of Selective Laser Melting for Forming TI6AL4V Samples by Taguchi Method,” Optics & Laser Technology, Vol. 49, pp. 118–124, 2013.
Yadroitsev, I., Yadroitsava, I., Bertrand, P., and Smurov, I., “Factor Analysis of Selective Laser Melting Process Parameters and Geometrical Characteristics of Synthesized Single Tracks,” Rapid Prototyping Journal, Vol. 18, No. 3, pp. 201–208, 2012.
Loh, L.-E., Chua, C.-K., Yeong, W.-Y., Song, J., Mapar, M., et al., “Numerical Investigation and an Effective Modelling on the Selective Laser Melting (SLM) Process with Aluminium Alloy 6061,” International Journal of Heat and Mass Transfer, Vol. 80, pp. 288–300, 2015.
Hebert, R. J., “Viewpoint: Metallurgical Aspects of Powder Bed Metal Additive Manufacturing,” Journal of Materials Science, Vol. 51, No. 3, pp. 1165–1175, 2016.
Craeghs, T., Clijsters, S., Yasa, E., and Kruth, J.-P., “Online Quality Control of Selective Laser Melting”, Proc of the Solid Freeform Fabrication Symposium, pp. 212-226, 2011.
Kruth, J.-P., Mercelis, P., Van Vaerenbergh, J., and Craeghs, T., “Feedback Control of Selective Laser Melting,” Proc. of the 3rd International Conference on Advanced Research in Virtual and Rapid Prototyping, pp. 521–527, 2007.
Kruth, J.-P., Duflou, J., Mercelis, P., Van Vaerenbergh, J., Craeghs, T., et al., “On-Line Monitoring and Process Control in Selective Laser Melting and Laser Cutting,” Proc. of the 5th Lane Conference, Laser Assisted Net Shape Engineering, pp. 23–37, 2007.
Kruth, J.-P. and Mercelis, P., “Procedure and Apparatus for In-Situ Monitoring and Feedback Control of Selective Laser Powder Processing,” US Patent, 20090206065 A1, 2007.
Craeghs, T., Clijsters, S., Yasa, E., Bechmann, F., Berumen, S., et al., “Determination of Geometrical Factors in Layerwise Laser Melting Using Optical Process Monitoring,” Optics and Lasers in Engineering, Vol. 49, No. 12, pp. 1440–1446, 2011.
Lott, P., Schleifenbaum, H., Meiners, W., Wissenbach, K., Hinke, C., et al., “Design of an Optical System for the in Situ Process Monitoring of Selective Laser Melting (SLM),” Physics Procedia, Vol. 12, pp. 683–690, 2011.
Clijsters, S., Craeghs, T., Buls, S., Kempen, K., and Kruth, J.-P., “In Situ Quality Control of the Selective Laser Melting Process Using a High-Speed, Real-Time Melt Pool Monitoring System,” The International Journal of Advanced Manufacturing Technology, Vol. 75, Nos. 5-8, pp. 1089–1101, 2014.
Kleszczynski, S., Zur Jacobsmühlen, J., Sehrt, J., and Witt, G., “Error Detection in Laser Beam Melting Systems by High Resolution Imaging,” Proc. of the 23th Annual International Solid Freeform Fabrication Symposium, 2012.
Berumen, S., Bechmann, F., Lindner, S., Kruth, J.-P., and Craeghs, T., “Quality Control of Laser-and Powder Bed-Based Additive Manufacturing (AM) Technologies,” Physics Procedia, Vol. 5, pp. 617–622, 2010.
Thombansen, U. and Abels, P., “Observation of Melting Conditions in Selective Laser Melting of Metals (SLM),” SPIE LASE, Paper No. 97410S, 2016.
Chivel, Y. and Smurov, I., “On-Line Temperature Monitoring in Selective Laser Sintering/Melting,” Physics Procedia, Vol. 5, pp. 515–521, 2010.
Doubenskaia, M., Pavlov, M., and Chivel, Y., “Optical System for On-Line Monitoring and Temperature Control in Selective Laser Melting Technology,” Key Engineering Materials, pp. 458–461, 2010.
Bayle, F. and Doubenskaia, M., “Selective Laser Melting Process Monitoring with High Speed Infra-Red Camera and Pyrometer,” Proc. of Fundamentals of Laser Assisted Micro-and Nanotechnologies, Paper No. 698505, 2008.
Doubenskaia, M., Pavlov, M., Grigoriev, S., Tikhonova, E., and Smurov, I., “Comprehensive Optical Monitoring of Selective Laser Melting,” Journal of Laser Micro Nanoengineering, Vol. 7, No. 3, pp. 236–243, 2012.
Doubenskaia, M. A., Zhirnov, I. V., Teleshevskiy, V. I., Bertrand, P., and Smurov, I. Y., “Determination of True Temperature in Selective Laser Melting of Metal Powder Using Infrared Camera,” Proc. of Materials Science Forum, pp. 93–102, 2015.
Krauss, H., Eschey, C., and Zaeh, M., “Thermography for Monitoring the Selective Laser Melting Process,” Proc. of the Solid Freeform Fabrication Symposium, 2012.
Hua, T., Jing, C., Xin, L., Fengying, Z., and Weidong, H., “Research on Molten Pool Temperature in the Process of Laser Rapid Forming,” Journal of Materials Processing Technology, Vol. 198, No. 1, pp. 454–462, 2008.
Griffith, M., Schlienger, M., Harwell, L., Oliver, M., Baldwin, M., et al., “Understanding Thermal Behavior in the Lens Process,” Materials & Design, Vol. 20, No. 2, pp. 107–113, 1999.
Tadamalle, A., Reddy, Y., and Ramjee, E., “Influence of Laser Welding Process Parameters on Weld Pool Geometry and Duty Cycle,” Advances in Production Engineering & Management, Vol. 8, No. 1, p. 52, 2013.
Cus, F., Zuperl, U., and Irgolic, T., “Effects of Laser Cladding Parameters on Microstructure Properties and Surface Roughness of Graded Material,” Proceedings in Manufacturing Systems, Vol. 10, No. 2, p. 77, 2015.
Balu, P., Leggett, P., and Kovacevic, R., “Parametric Study on a Coaxial Multi-Material Powder Flow in Laser-Based Powder Deposition Process,” Journal of Materials Processing Technology, Vol. 212, No. 7, pp. 1598–1610, 2012.
Wang, L. and Felicelli, S., “Analysis of Thermal Phenomena in LENS™ Deposition,” Materials Science and Engineering: A, Vol. 435, pp. 625–631, 2006.
Unocic, R. and Du Pont, J., “Process Efficiency Measurements in the Laser Engineered Net Shaping Process,” Metallurgical and Materials Transactions B, Vol. 35, No. 1, pp. 143–152, 2004.
Doumanidis, C. and Kwak, Y.-M., “Geometry Modeling and Control by Infrared and Laser Sensing in Thermal Manufacturing with Material Deposition,” Journal of Manufacturing Science and Engineering, Vol. 123, No. 1, pp. 45–52, 2001.
Hu, D. and Kovacevic, R., “Sensing, Modeling and Control for Laser-Based Additive Manufacturing,” International Journal of Machine Tools and Manufacture, Vol. 43, No. 1, pp. 51–60, 2003.
Hu, D., Mei, H., and Kovacevic, R., “Improving Solid Freeform Fabrication by Laser-Based Additive Manufacturing,” Poceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 216, No. 9, pp. 1253–1264, 2002.
David, S., Babu, S., and Vitek, J., “Welding: Solidification and Microstructure,” Journal of the Minerals, Metals and Materials Society, Vol. 55, No. 6, pp. 14–20, 2003.
Colodrón, P., Fariña, J., Rodríguez-Andina, J. J., Vidal, F., Mato, J. L., et al., “Performance Improvement of a Laser Cladding System through FPGA-Based Control,” Proc. of 37th Annual Conference on IEEE Industrial Electronics Society, pp. 2814–2819, 2011.
Araújo, J. R., Rodríguez-Andina, J. J., Fariña, J., Vidal, F., Mato, J. L., et al., “FPGA-Based Laser Cladding System with Increased Robustness to Optical Defects,” Proc. of 38th Annual Conference on IEEE Industrial Electronics Society, pp. 4688–4693, 2012.
Hofman, J., Pathiraj, B., Van Dijk, J., De Lange, D., and Meijer, J., “A Camera Based Feedback Control Strategy for the Laser Cladding Process,” Journal of Materials Processing Technology, Vol. 212, No. 11, pp. 2455–2462, 2012.
Mozaffari, A., Fathi, A., Khajepour, A., and Toyserkani, E., “Optimal Design of Laser Solid Freeform Fabrication System and Real-Time Prediction of Melt Pool Geometry Using Intelligent Evolutionary Algorithms,” Applied Soft Computing, Vol. 13, No. 3, pp. 1505–1519, 2013.
Griffith, M. L., Ensz, M. T., Puskar, J. D., Robino, C. V., Brooks, J. A., et al., “Understanding the Microstructure and Properties of Components Fabricated by Laser Engineered Net Shaping (LENS),” Materials Research Society, Vol. 625, p. 9, 2000.
Hofmeister, W., Wert, M., Smugeresky, J., Philliber, J. A., Griffith, M., et al., “Investigating Solidification with the Laser-Engineered Net Shaping (LENSTM) Process,” Journal of the Minerals, Metals & Materials Society, Vol. 51, No. 7, pp. 1–6, 1999.
Hofmeister, W. and Griffith, M., “Solidification in Direct Metal Deposition by LENS Processing,” Journal of the Minerals, Metals & Materials Society, Vol. 53, No. 9, pp. 30–34, 2001.
Bi, G., Gasser, A., Wissenbach, K., Drenker, A., and Poprawe, R., “Identification and Qualification of Temperature Signal for Monitoring and Control in Laser Cladding,” Optics and Lasers in Engineering, Vol. 44, No. 12, pp. 1348–1359, 2006.
Bi, G., Gasser, A., Wissenbach, K., Drenker, A., and Poprawe, R., “Investigation on the Direct Laser Metallic Powder Deposition Process Via Temperature Measurement,” Applied Surface Science, Vol. 253, No. 3, pp. 1411–1416, 2006.
Bi, G., Schürmann, B., Gasser, A., Wissenbach, K., and Poprawe, R., “Development and Qualification of a Novel Laser-Cladding Head with Integrated Sensors,” International Journal of Machine Tools and Manufacture, Vol. 47, No. 3, pp. 555–561, 2007.
Bi, G., Sun, C., and Gasser, A., “Study on Influential Factors for Process Monitoring and Control in Laser Aided Additive Manufacturing,” Journal of Materials Processing Technology, Vol. 213, No. 3, pp. 463–468, 2013.
Moralejo, S., Penaranda, X., Nieto, S., Barrios, A., Arrizubieta, I., et al., “A Feedforward Controller for Tuning Laser Cladding Melt Pool Geometry in Real Time,” The International Journal of Advanced Manufacturing Technology, pp. 1–11, 2016.
Karnati, S., Matta, N., Sparks, T., and Liou, F., “Vision-Based Process Monitoring for Laser Metal Deposition Processes,” Proc. of the 24th Annual International Solid Freeform Fabrication Symposium, 2013.
Farshidianfar, M. H., Khajepour, A., and Gerlich, A. P., “Effect of Real-Time Cooling Rate on Microstructure in Laser Additive Manufacturing,” Journal of Materials Processing Technology, Vol. 231, pp. 468–478, 2016.
Farshidianfar, M. H., Khajepour, A., and Gerlich, A., “Real-Time Control of Microstructure in Laser Additive Manufacturing,” The International Journal of Advanced Manufacturing Technology, Vol. 82, Nos. 5-8, pp. 1173–1186, 2016.
Purtonen, T., Kalliosaari, A., and Salminen, A., “Monitoring and Adaptive Control of Laser Processes,” Physics Procedia, Vol. 56, pp. 1218–1231, 2014.
Jacob, G., Donmez, A., Slotwinski, J., and Moylan, S., “Measurement of Powder Bed Density in Powder Bed Fusion Additive Manufacturing Processes,” Measurement Science and Technology, Vol. 27, No. 11, Paper No. 115601, 2016.
Lee, J. and Prabhu, V., “Simulation Modeling for Optimal Control of Additive Manufacturing Processes,” Additive Manufacturing, Vol. 12, pp. 197–203, 2016.
Kamath, C., “On the Use of Data Mining Techniques to Build High-Density, Additively-Manufactured Parts,” in: Information Science for Materials Discovery and Design, Lookman, T., Alexander, F. J., and Rajan, K., (Eds.), Springer, pp. 141–155, 2016.
Tapia, G., Elwany, A., and Sang, H., “Prediction of Porosity in Metal-Based Additive Manufacturing Using Spatial Gaussian Process Models,” Additive Manufacturing, Vol. 12, pp. 282–290, 2016.
Lei, N., Yao, X., Moon, S. K., and Bi, G., “An Additive Manufacturing Process Model for Product Family Design,” Journal of Engineering Design, Vol. 27, No. 11, pp. 751–767, 2016.
Yao, X., Moon, S. K., and Bi, G., “Multidisciplinary Design Optimization to Identify Additive Manufacturing Resources in Customized Product Development,” Journal of Computational Design and Engineering, 2016. (DOI: http://dx.doi.org/10.1016/j.jcde.2016.10.001)
Zheng, B., Yang, N., Yee, J., Gaiser, K., Lu, W., et al., “Review on Laser Powder Injection Additive Manufacturing of Novel Alloys and Composites,” Proc. of Laser 3D Manufacturing III, 2016.
Kenel, C., Grolimund, D., Fife, J., Samson, V., Van Petegem, S., et al., “Combined in Situ Synchrotron Micro X-Ray Diffraction and High-Speed Imaging on Rapidly Heated and Solidified TI-48AL Under Additive Manufacturing Conditions,” Scripta Materialia, Vol. 114, pp. 117–120, 2016.
Rodriguez, E., Medina, F., Espalin, D., Terrazas, C., Muse, D., et al., “Integration of a Thermal Imaging Feedback Control System in Electron Beam Melting,” Proc. of the Solid Freeform Fabrication Symposium, pp. 945–961, 2012.
Rodriguez, E., Mireles, J., Terrazas, C. A., Espalin, D., Perez, M. A., et al., “Approximation of Absolute Surface Temperature Measurements of Powder Bed Fusion Additive Manufacturing Technology Using in Situ Infrared Thermography,” Additive Manufacturing, Vol. 5, pp. 31–39, 2015.
Schomer, J. J., Hehr, A. J., and Dapino, M. J., “Characterization of Embedded Fiber Optic Strain Sensors into Metallic Structures Via Ultrasonic Additive Manufacturing,” Proc. of SPIE Smart Structures and Materials + Nondestructive Evaluation and Health Monitoring, Paper No. 980320, 2016.
Dunbar, A. J., Denlinger, E. R., Heigel, J., and Simpson, T. W., “Experimental in Situ Distortion and Temperature Measurements during the Laser Powder Bed Fusion Additive Manufacturing Process Part 1: Development of Experimental Method,” Additive Manufacturing, 2016. (DOI: 10.1016/j.addma.2016.04.007)
Seifi, M., Salem, A., Beuth, J., Harrysson, O., and Lewandowski, J. J., “Overview of Materials Qualification Needs for Metal Additive Manufacturing,” Journal of the Minerals, Metals & Materials Society, Vol. 68, No. 3, pp. 747–764, 2016.
Carl, V., Chimenti, D. E., and Bond, L. J., “Monitoring System for the Quality Assessment in Additive Manufacturing,” Proc. of AIP Conference, pp. 171–176, 2015.
Du Plessis, A., le Roux, S. G., Booysen, G., and Els, J., “Directionality of Cavities and Porosity Formation in Powder-Bed Laser Additive Manufacturing of Metal Components Investigated Using X-Ray Tomography,” 3D Printing and Additive Manufacturing, Vol. 3, No. 1, pp. 48–55, 2016.
Manzo, A., Kenderian, S., and Helvajian, H., “Application of Laser Ultrasonic Non-Destructive Evaluation Technique to Additive Manufacturing,” Proc. of SPIE LASE, Paper No. 973810, 2016.
Everton, S. K., Hirsch, M., Stravroulakis, P., Leach, R. K., and Clare, A. T., “Review of In-Situ Process Monitoring and In-Situ Metrology for Metal Additive Manufacturing,” Materials & Design, Vol. 95, No. 5, pp. 431–445, 2016.
Foster, B. K., Reutzel, E. W., Nassar, A. R., Dickman, C. J., and Hall, B. T., “A Brief Survey of Sensing for Metal-Based Powder Bed Fusion Additive Manufacturing,” Proc. of SPIE Sensing Technology + Applications, Paper No. 94890B, 2015.
Spears, T. G. and Gold, S. A., “In-Process Sensing in Selective Laser Melting (SLM) Additive Manufacturing,” Integrating Materials and Manufacturing Innovation, Vol. 5, No. 1, pp. 1–25, 2016.
Moon, S. K., Kumara, S. R., and Simpson, T. W., “Knowledge Representation for Product Design Using Techspecs Concept Ontology,” Proc. of IEEE International Conference on Information Reuse and Integration, pp. 241–246, 2005.
Moon, S. K., Simpson, T. W., Shu, J., and Kumara, S. R., “Service Representation for Capturing and Reusing Design Knowledge in Product and Service Families Using Object-Oriented Concepts and an Ontology,” Journal of Engineering Design, Vol. 20, No. 4, pp. 413–431, 2009.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Chua, Z.Y., Ahn, I.H. & Moon, S.K. Process monitoring and inspection systems in metal additive manufacturing: Status and applications. Int. J. of Precis. Eng. and Manuf.-Green Tech. 4, 235–245 (2017). https://doi.org/10.1007/s40684-017-0029-7
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40684-017-0029-7