In situ build surface topography determination in electron beam powder bed fusion

Abstract

AbstractElectron optical imaging is the most promising process monitoring method in electron beam powder bed fusion. State of the art in modern machines is the installation of a single detector in the top center of the build chamber. Exemplary applications are the reconstruction of digital twins of manufactured parts to compare their dimensional accuracy or analysing the top surface of each layer to identify surface features like pores or material transport. Multi-detector systems are currently under research and have shown great potential in reconstructing the surface topography in situ. A recently developed ray tracing model, describing the image formation process, allows to formulate design guide lines for multi-detector systems and provides a method for the computation of the normal vector field of the build surface. This work utilizes the recent progress and presents a newly developed four-detector system and an updated computation chain, which enable build surface topography reconstruction in situ in every layer of a build process. The computation chain contains a normal integration algorithm, which employs Tikhonov regularization to cope with measurement irregularities. The integration method is validated with ex situ measured as-built surfaces. Additionally, first applications are demonstrated and connections to process parameter changes illustrated.