Abstract
Abstract. An increasing number of additive manufacturing (AM) applications leads to rising challenges for the process-accompanying quality assurance. Beside post-processing measurement systems, in situ monitoring systems in particular are currently requested to ensure feedback controlling during AM processes. For data acquisition and subsequent evaluation, a high data quality is of importance. It depends on a high resolution and accuracy of measurement systems, adapted measurement conditions and a reference to the powder bed or component for geometric measurements. Within this scientific study, a new reference system has been implemented into the powder bed to reduce measurement deviations by an abbreviated metrological loop. After data acquisition and image processing layer by layer, the position stability of the reference system has been analysed in relation to the optical measuring system. Based on a contour detection of the reference markers, the evaluation of geometrical process deviations is presented as an essential basis for a closed-loop controlling system. Thermally induced and mechanical drifts within the manufacturing process can be verified by the reference system in the powder bed. As an outlook, two methods are suggested for a process-accompanying referenced detection of the melting pool and resulting contour displacements during additive manufacturing.
Highlights
Additive manufacturing (AM) is the general term for processes that are based on a successive addition of materials (ISO/ASTM-52900, 2015)
It has been shown that the presented referencing concept can be used as a stable reference system for process monitoring
The directional influence of the powder application system has been identified as the main influence of lateral manufacturing displacements
Summary
Additive manufacturing (AM) is the general term for processes that are based on a successive addition of materials (ISO/ASTM-52900, 2015) In general it is known as rapid prototyping (RP) or 3-D printing, which can be divided in numerous process categories (Schmidt et al, 2017; Gebhard et al, 2019). These are characterised by different materials, binding mechanisms and associated different processing steps. In focus of this scientific study is generally the process group of powder bed fusion (PBF) systems as a representative of laser-based process categories. The measurements of the individual layers should be referenced to each other by a shortened measuring loop of the powder bed and not by the otherwise usual long measuring loop of the entire AM plant
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