TY - JOUR A1 - Oster, Simon A1 - Fritsch, Tobias A1 - Ulbricht, Alexander A1 - Mohr, Gunther A1 - Bruno, Giovanni A1 - Maierhofer, Christiane A1 - Altenburg, Simon T1 - On the registration of thermographic in situ monitoring data and computed tomography reference data in the scope of defect prediction in laser powder bed fusion JF - Metals : open access journal N2 - The detection of internal irregularities is crucial for quality assessment in metal-based additive manufacturing (AM) technologies such as laser powder bed fusion (L-PBF). The utilization of in-process thermography as an in situ monitoring tool in combination with post-process X-ray micro computed tomography (XCT) as a reference technique has shown great potential for this aim. Due to the small irregularity dimensions, a precise registration of the datasets is necessary as a requirement for correlation. In this study, the registration of thermography and XCT reference datasets of a cylindric specimen containing keyhole pores is carried out for the development of a porosity prediction model. The considered datasets show variations in shape, data type and dimensionality, especially due to shrinkage and material elevation effects present in the manufactured part. Since the resulting deformations are challenging for registration, a novel preprocessing methodology is introduced that involves an adaptive volume adjustment algorithm which is based on the porosity distribution in the specimen. Thus, the implementation of a simple three-dimensional image-to-image registration is enabled. The results demonstrate the influence of the part deformation on the resulting porosity location and the importance of registration in terms of irregularity prediction. KW - selective laser melting (SLM) KW - laser powder bed fusion (L-PBF) KW - additive KW - manufacturing (AM) KW - process monitoring KW - infrared thermography KW - X-ray KW - micro computed tomography (XCT) KW - defect detection KW - image registration Y1 - 2022 U6 - https://doi.org/10.3390/met12060947 SN - 2075-4701 VL - 12 IS - 6 PB - MDPI CY - Basel ER - TY - JOUR A1 - Ulbricht, Alexander A1 - Mohr, Gunther A1 - Altenburg, Simon J. A1 - Oster, Simon A1 - Maierhofer, Christiane A1 - Bruno, Giovanni T1 - Can potential defects in LPBF be healed from the laser exposure of subsequent layers? BT - A quantitative study JF - Metals : open access journal N2 - Additive manufacturing (AM) of metals and in particular laser powder bed fusion (LPBF) enables a degree of freedom in design unparalleled by conventional subtractive methods. To ensure that the designed precision is matched by the produced LPBF parts, a full understanding of the interaction between the laser and the feedstock powder is needed. It has been shown that the laser also melts subjacent layers of material underneath. This effect plays a key role when designing small cavities or overhanging structures, because, in these cases, the material underneath is feed-stock powder. In this study, we quantify the extension of the melt pool during laser illumination of powder layers and the defect spatial distribution in a cylindrical specimen. During the LPBF process, several layers were intentionally not exposed to the laser beam at various locations, while the build process was monitored by thermography and optical tomography. The cylinder was finally scanned by X-ray computed tomography (XCT). To correlate the positions of the unmolten layers in the part, a staircase was manufactured around the cylinder for easier registration. The results show that healing among layers occurs if a scan strategy is applied, where the orientation of the hatches is changed for each subsequent layer. They also show that small pores and surface roughness of solidified material below a thick layer of unmolten material (>200 mu m) serve as seeding points for larger voids. The orientation of the first two layers fully exposed after a thick layer of unmolten powder shapes the orientation of these voids, created by a lack of fusion. KW - selective laser melting (SLM) KW - additive manufacturing (AM) KW - process KW - monitoring KW - infrared thermography KW - optical tomography KW - X-ray computed KW - tomography (XCT) KW - healing KW - in situ monitoring Y1 - 2021 U6 - https://doi.org/10.3390/met11071012 SN - 2075-4701 VL - 11 IS - 7 PB - MDPI CY - Basel ER - TY - JOUR A1 - Sprengel, Maximilian A1 - Mohr, Gunther A1 - Altenburg, Simon J. A1 - Evans, Alexander A1 - Serrano-Munoz, Itziar A1 - Kromm, Arne A1 - Pirling, Thilo A1 - Bruno, Giovanni A1 - Kannengießer, Thomas T1 - Triaxial residual stress in Laser Powder Bed Fused 316L BT - effects of interlayer time and scanning velocity JF - Advanced engineering materials N2 - The control of residual stress (RS) remains a challenge in the manufacturing of metallic parts using the laser powder bed fusion process (LPBF). This layer-by-layer manufacturing approach gives rise to complex triaxial RS distributions, which require extensive characterization effort for a broader acceptance of LPBF in industry. This study focuses on the distribution of bulk triaxial RS and surface RS in LPBF austenitic steel 316L. The RS are determined by X-ray and neutron diffraction to characterize the RS distribution. Variations in the LPBF parameters interlayer time (ILT) and scanning velocity and their influence on the temperature distribution and resulting RS is investigated using thermographic data from in situ process monitoring. The RS in the LPBF 316L is tensile at the surface and compressive in the bulk. The RS is directly related to the thermal history of the part as shown by the in situ thermography data. Shorter ILT leads to higher temperatures of the part during the manufacturing, which decrease the RS and RS formation mechanisms. Interestingly, the surface RS does not agree with this observation. This study highlights the benefit of using multiple RS determination methods and in situ thermography monitoring to characterize the RS in LPBF processed parts. KW - in situ thermography KW - interlayer time KW - laser powder bed fusions KW - triaxial residual stresses KW - X-ray and neutron diffractions Y1 - 2021 U6 - https://doi.org/10.1002/adem.202101330 SN - 1438-1656 SN - 1527-2648 VL - 24 IS - 6 PB - Wiley-VCH CY - Weinheim ER -