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Meeting MS&T22: Materials Science & Technology
Symposium Additive Manufacturing: Equipment, Instrumentation and In-Situ Process Monitoring
Presentation Title Real-time, High-speed and High-resolution Multi- and Hyperspectral Imaging of Powder Bed Fusion
Author(s) Steven Storck, Mark Foster, Nathan Drenkow, Brendan Croom, Milad Alemohammad, Christopher Stiles, Bobby Mueller, Michael Pekala, Mary Dafron, Ryan Carter, Dylan Madisetti
On-Site Speaker (Planned) Steven Storck
Abstract Scope Laser-powder-bed-fusion (L-PBF) has become a prime candidate for the aerospace and medical fields, which have challenging qualification requirements. Stringent qualification/certification standards are the main limiting factors for part acceptance, resulting in significant time and >60% of the cost to develop a final component. Real-time monitoring of L-PBF to detect defect formation and processing anomalies will significantly increase engineering certainty. This will significantly reduce qualification and certification costs and time, enabling AM in more applications and industries. Our team developed a custom high-speed hyperspectral sensor and high speed multicolor pyrometer that tracks the thermal signature of the laser melt pool at up to 500 KHz. Data is correlated with spatial porosity and analyzed with machine learning, correlating spectral characteristics to process anomalies. This talk will cover sensor development, detection of laser-induced defects and thermal anomalies using hyper- and multi-spectral imaging, machine learning analysis, and validation using 3-dimensional X-ray computed tomography analysis.

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A-18: Development of an IEP Apparatus for 3D Printing of Thermoelectric Material
A-19: In-process Microstructure Sensing of Gr91 Powder Bed Fusion Parts Using Ultrasonics
A-20: Real-time Process Monitoring for Multivariate Statistical Process Control in Powder Bed Fusion Metal Additive Manufacturing
A-21: Quantification of Melt Pool Variability for L-PBF Additive Manufacturing by High-Speed Imaging
Additive Manufacturing Standardization Landscape and Recent Initiatives Advancing Standards Development
Additive Materials Data: Truths and Myths
AM Materials Data – Challenges and Opportunities
An Intelligent Data Infrastructure for Additive Manufacturing
Automated Detection and Quantification of Spatter Generated During Laser Powder Bed Fusion Using Infrared Imaging and Computer Vision
Challenges and Opportunities for In-Situ Sensing during Electron Beam Powder Bed Fusion Additive Manufacturing
Characterization of Laser Powder Bed Fusion Internal and Surface Defects as a Foundation for In Situ Monitoring
Design of a Glovebox for In Situ Monitoring of a Directed Energy Deposition Process
Exploring Synchronized Dual Laser Scan Strategies for Increased Productivity of Laser Powder Bed Fusion
High-Speed Thermal Imaging of the Melt Pool in Laser Powder Bed Fusion
In-situ Monitoring of the EBM Process: From Powder Bed Homogeneity to Thermal Signatures
In-situ Process Monitoring of Laser Powder Bed Fusion Additive Manufacturing Using Thermionic Emission Detection
In-situ Process Monitoring, Synchronization and Mapping Laser Powder Bed Fusion Builds of Ti6Al4V
In-situ Sensor Feature Engineering for Process Development of Energy Conversion Materials
Instrumenting an EOS M290 with a Smart Build-Plate
Investigating the Use of In-situ Weld Pool Characteristics and Temperature Measurements for Monitoring Part Quality in Wire Arc Additive Manufacturing
Melt Pool-Scale Process Monitoring of Laser Powder Bed Fusion
Microstructure Control during Wire and Arc Additive Manufacturing
New Standardization Efforts to Collect, Correlate, and Identify Metrics of Reuse Powder with Functional Performance Data of Material Resultant of Additive Manufacturing Workflows
Optimization of Laser Powder Bed Fusion AM through Process Gas Control 
Process Monitoring of Melt Pool Spatter at Melt Pool, Layer and Part Scales
Providing a Rigorous Benchmark Measurement Foundation for Modeling-Informed Qualification and Certification of Metal AM Components
Real-time, High-speed and High-resolution Multi- and Hyperspectral Imaging of Powder Bed Fusion
Research and Standards Development Needs for AM Industrialization
Role of Interstitial Alloying Elements on Microstructural Evolution in Additively Manufactured Materials
Scientific Foundations and Approaches for Qualification of Additively Manufactured Structural Components
Several Ways Ultrasound Can Be Used during Powder Bed Fusion
Using High-Speed Thermal Imaging to Understand Melt Pool Defects in Laser Powder Bed Fusion
Wire DED Process Monitoring and Controls

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