Laser Metal Deposition Process Research Articles

Tribological investigation of new self-fluxing nickel alloys for high temperature application: the effect of silicon distribution on glaze layer formation

The objective of this study is to investigate the tribological performance of new nickel-based self-fluxing alloys for replacing cobalt-based alloys in aircraft components. Two new NiCrSiFeB alloys, manufactured by gravity casting and laser metal deposition processes, having different microstructures, are submitted to fretting loadings and tested at temperatures ranging from ambient to 650 °C. Their wear behavior is compared to a reference Stellite 6 cobalt- based alloy. Although the two NiCrSiFeB alloys have the same chemical composition, the alloy having a coarse microstructure rich in silicates was able to form a protective glaze layer at high temperature as Stellite 6. On the other hand, the alloy having a fine microstructure underwent severe adhesive wear. This highlights the crucial effect of the microstructure and the silicon distribution in activating the formation of a protective glaze layer at high temperatures.

Thermodynamic behavior and microstructure evolution of Inconel 718 alloy by laser metal deposition

The temperature evolution, stress evolution, and dendrite growth during the laser metal deposition (LMD) process of Inconel 718 alloy were simulated using a multi-scale model that combines the finite element method and the Cellular Automata (CA) method. This model established the relationship between the thermal behavior of the molten pool and the solidification characteristics, and predicted the morphological size of the solidified structure. Research indicates that under conditions of higher cooling rate and lower shape control factor, equiaxed grains are prone to form, with a lower degree of elemental segregation in this region, which is conducive to the precipitation of granular Laves phase. Conversely, under conditions of lower cooling rate and higher shape control factor, columnar grains are more likely to form, with a higher degree of elemental segregation in this region, leading to the precipitation of chain-like Laves phase. The results of thermo-mechanical coupled simulation suggest that the maximum transient thermal stress is located at the overlap position, and when the component cools down to room temperature, the maximum normal stress along the scanning direction is observed. Dendritic growth results demonstrate that during the equiaxed grain growth process in the top region of the melt pool, the released solute is constrained by time and space, leading to the accumulation of solute and the formation of interdendritic segregation. In areas with a higher grain density, the solute accumulation zones overlap, resulting in an increase in solute concentration, which inhibits dendrite growth. In the middle region of the melt pool, during the columnar grain growth process, the solute concentration in the gaps between adjacent grains continuously increases, resulting in micro-segregation phenomena. Experimental measurements have shown that the temperature field's melt pool morphology, stress values along the scanning path, and dendritic morphology are in good agreement with the experimental outcomes.

Repair of heat load damaged plasma–facing material using the wire-based laser metal deposition process

Due to its unique properties tungsten is a promising candidate as plasma-facing-material (PFM) in future nuclear fusion reactors. Tungsten features an exceptionally high melting point, high thermal conductivity, low tritium inventory and comparatively low erosion rate under plasma loading [1]. But given the extreme loads on the PFM during operation of a fusion reactor, the lifetime of plasma-facing components (PFC)s is limited. Currently, it is planned to replace damaged PFCs when they reach the end of their service life. However, the lifetime of PFCs could be increased by in situ repair using additive manufacturing technology (AM) in the form of direct-energy-deposition (DED). The wire–based laser metal deposition process (LMD-w) meets several necessary conditions for operation in the vessel and could be used for performing such in situ repairs.It was investigated if the LMD-w process is able to heal thermal induced surface cracks and roughening by remelting the substrate during deposition of tungsten. For this purpose, tungsten samples of 12 × 12 × 5mm3, which later served as substrate plates for the LMD-w experiments, were treated with combined steady-state and transient thermal loads in the electron beam facility JUDITH 2. These samples were brazed to a copper cooling structure and exposed to 105 thermal shocks of 0.5 ms duration and an intensity of Labs = 0.55 GW m−2 (FHF = 12 MW s0,5 m−2) at a base temperature of Tbase = 700 °C. This way, edge localized mode (ELM) like thermal load damage was induced on the tungsten samples. On these samples, different LMD-w and laser remelting process strategies were performed. Subsequently, these samples were analyzed, and it was examined that the healing of the pre-damaged substrate material was successful. In parallel, the laser remelting process was modeled in a thermal transient finite element method(FEM) simulation in order to gain an insight into the temperatures prevailing in the material during the process.

TEMPERATURE MONITORING FOR LASER METAL DEPOSITION USING NEAR-INFRARED SPECTROSCOPY

Temperature monitoring during laser metal deposition (LMD) aids process control to ensure high-quality production. However, the fluctuating emissivity of the melt pool limits the accuracy of the existing non-contact temperature measuring devices. Thus, this work explores a new temperature monitoring technique, where the thermal radiation emitted by the processing zone was collected with a near-infrared (NIR) spectrometer and fitted to Planck's law to determine the temperature. This work has established the optimised angle and distance of the fiber probe from the LMD processing area to maximise the spectral signal acquisition. The temperature determined from the technique was cross-validated with a thermocouple, resulted in a small deviation of 2.39%. The applicability of the spectroscopic method for continuous temperature monitoring of the LMD process has been demonstrated. The optimised placement for the fiber probe end was determined at the 45˚ angle relative to the surface of the substrate and positioned 5 cm away from the molten pool. The temperature during the LMD process decreased gradually then stabilised after approximately 17 mm track length, resembling those reports in prior studies. Our findings support the practicality of the proposed temperature monitoring approach in LMD.

Influence of the inner roughness of powder channels on the powder propagation behavior in laser metal deposition

The powder propagation behavior of powder nozzles for the laser metal deposition process has a significant influence on powder utilization rate and track geometry. A well-focused powder stream will lead to a higher process efficiency and lower material loss. Powder channels with different roughness and a constant diameter of 1.5 mm were placed by wire electrical discharge machining into a copper alloy printed by powder bed fusion. Nickel base powder with a size of −106 to +45 μm was delivered through the powder channels with varied carrier gas flow rates and varied powder mass flow rates. High-speed imaging was used to analyze the powder flow. From these recordings, the dispersion angle of the powder stream from single channels could be measured as well as the velocity of particles. Moreover, the relationship between individual particle velocity and individual particle flight angle was investigated. It was found that the inner roughness of powder channels has a major impact on powder propagation behavior. It could be shown that with a decrease in Ra from 2.16 to 0.27 μm the divergence angle decreased by around 61% while the particle velocity was increased by at least 28% for all varied parameters. Particles with a high velocity tend to have a lower particle flight angle.

Additive manufacturing of titanium–diamond parts: insights into the laser metal deposition process, powder rheology, mechanical properties and osteoblast cell viability

PurposeThe purpose of this study is therefore to detail an additive manufacturing process for printing TiD parts for implant applications. Titanium–diamond (TiD) is a new composite that provides biocompatible three-dimensional multimaterial structures. Thus, the authors report a powder-deposition and print optimization strategy to overcome the dual-functionality gap by printing bulk TiD parts. However, despite favorable customization outcomes, relatively few additive manufacturing (AM) feedstock powders offer the biocompatibility required for medical implant and device technologies.Design/methodology/approachAM offers a platform to fabricate customized patient-specific parts. Developing feedstock that can be 3D printed into specific 3D structures while providing a favorable interface with the human tissue remains a challenge. Using laser metal deposition, feedstock powder comprising diamond and titanium was co-printed into TiD parts for mechanical testing to determine optimal manufacturing parameters.FindingsTiD parts were fabricated comprising 30% and 50% diamond. The composite powder had a Hausner ratio of 1.13 and 1.21 for 30% and 50% TiD, respectively. The flow analysis (Carney flow) for TiD 30% and 50% was 7.53 and 5.15 g/s. The authors report that the printing-specific conditions significantly affect the integrity of the printed part and thus provide the optimal manufacturing parameters for structural integrity as determined by micro-computed tomography, nanoindentation and biocompatibility of TiD parts. The hardness, ultimate tensile strength and yield strength for TiD are 4–6 GPa (depending on build position), 426 MPa and 375 MPa, respectively. Furthermore, the authors show that increasing diamond composition to 30% results in higher osteoblast viability and lower bacteria count than titanium.Originality/valueIn this study, the authors provide a clear strategy to manufacture TiD parts with high integrity, performance and biocompatibility, expanding the material feedstock library and paving the way to customized diamond implants. Diamond is showing strong potential as a biomedical material; however, upscale is limited by conventional techniques. By optimizing AM as the avenue to make complex shapes, the authors open up the possibility of patient-specific diamond implant solutions.

Optimizing the maximum strain of a laser-deposited high-entropy alloy using COMSOL multiphysics

BackgroundLaser metal deposition (LMD) is a widely used additive manufacturing technique for producing complex high entropy alloys with special properties for several applications. The AlCoCrFeNiCu HEAs compositional design has six elements with a configurational entropy of 1.79 R and atomic concentrations between 5 and 35%, so the HEA system is thermodynamically favorable according to Boltzmann’s theory, attributed to the core effects. However, the high-entropy alloy has dominant Body-Centered Cubic structures which may be too brittle to be examined in tension experimentally. Preheating the substrate before and during layer deposition could be a potential solution that is currently under development since tensile loading necessitates an understanding of a material's behavior under tension through an analysis of its yield and ultimate tensile strength. A computer-aided design (CAD) solid model was used to generate the near-net dog-bone form of the alloy with moderately complicated geometrical characteristics using laser metal deposition (LMD) technology. This study investigates a straightforward and effective computational model for simulating material properties, using COMSOL Multiphysics 5.4 software for laser-deposited high entropy alloys that are excessively brittle to be tested in tension. The AlCoCrFeNiCu high-entropy alloy "dog bone" test sample was modeled using COMSOL Multiphysics for tensile loading. The first principal stresses and longitudinal strain under axial loading conditions were measured using a three-dimensional (3D) structural mechanics’ model.ResultsThe results showed the ultimate tensile strength is 8.47 N/m2, attributed to the high entropy effect and the dominant phase structure of the alloy.ConclusionNumerical models in this paper demonstrate the effect of stresses on the tensile behavior of the AlCoCrFeNiCu high-entropy alloy. The model optimizes the LMD process by analyzing residual stresses and predicting tensile strength, thus, providing insights that show the potential of high entropy alloys for structural integrity in aerospace applications.

Microstructure and mechanical property improvement of concurrent wire-powder feeding laser melting deposition Ti-6Al-4V via TiC addition

Wire-feed laser metal deposition (LMD-W) offers a high deposition rate and low cost, making it an effective solution for reducing costs and enhancing efficiency in manufacturing large-scale titanium aerospace components. Currently, the material used for LMD-W is typically a single alloy wire, which limits the flexibility and functionality of manufacturing composite materials. This work employed a novel concurrent wire-powder feeding laser metal deposition (LMD-WP) process to manufacture TiC/Ti-6Al-4V composite. In the LMD-WP method, Ti-6Al-4V wire was fed laterally, while TiC particles were delivered coaxially. Only 1.0 wt% TiC particles were added to prevent excessive TiC, which could cause stress concentration and increase crack sensitivity. The microstructure and mechanical properties of Ti-6Al-4V alloy and TiC/Ti-6Al-4V composite were investigated. The results indicate that with coaxial TiC particle addition, the α-Ti in TiC/Ti-6Al-4V is noticeably refined. Additionally, in situ TiC acts as heterogeneous nucleation sites, restricting α-Ti growth and reducing its aspect ratio. Furthermore, TiC particles weakened the α-Ti texture in the (0001) and (11–20) directions. Moreover, adding TiC particles significantly enhanced tensile strength, with the yield strength reaching 950 MPa and the ultimate tensile strength reaching 1048 MPa. Compared to Ti-6Al-4V alloy fabricated by LMD-W, this represents an increase of 11.25% and 10.72%, respectively. The improvement in tensile properties is principally ascribed to grain boundary strengthening, Orowan strengthening and dislocation density strengthening. This work introduces an innovative approach and abundant data for the additive manufacturing of TiC/Ti-6Al-4V composite with high efficiency and low cost.

Non-Planar Helical Path Generation Method for Laser Metal Deposition of Overhanging Thin-Walled Structures

Laser metal deposition is a branch of additive manufacturing that offers advantages over traditional manufacturing techniques for forming overhanging thin-walled metal parts. Previously, helical paths that were suitable for manufacturing such parts were not only limited to stacking material on a flat surface but were also fixed to the model boundaries. In order to solve these two problems to meet more complex process requirements, a non-planar helical path generation method is proposed for laser metal deposition. The method is based on the characteristics of the additive manufacturing process planning flow, which first slices the model using curved surfaces, then offsets the contours on the sliced layering, and finally generates continuous helical paths according to the contracted or expanded contours. In order to verify the feasibility of the method, hollow blades are formed on cylindrical surfaces following the planned paths. The results show that the proposed method is not only capable of assisting the laser metal deposition process to fabricate thin-walled structures on non-planar surfaces but also capable of freely adjusting the contour dimension.

Non-contact ultrasonic vibration-assisted laser metal deposition manufacturing Fe-based powder: Numerical simulation and experimental investigation

Fe-based powder was manufactured on 42CrMoA steel substrate using non-contact ultrasonic vibration-assisted(UVA) laser metal deposition(LMD) process with different exciting distances(d), and the temperature field and stress field distribution, microstructure and mechanical properties of the deposited layers were investigated. The results show that the distribution of temperature field was more uniform, especially at the bottom of the molten pool, and the gradient of temperature field decreased. Compared with the condition without UVA, the residual stress peak value of the tensile stress area decreased significantly after UVA applied. When d=80 mm, the peak tensile stress and compressive stress were 90.5 MPa and 72.6 MPa, respectively, which were reduced by 45.6 % and 25.2 % compared with the condition without UVA. The length of the columnar crystals and the region of the columnar crystals decreased at the interface after UVA applied. The application of UVA can significantly improved the microhardness of deposition layer. With the reduction of the residual stress at the interface and the improvement of uniformity, the tensile properties of the deposit were also significantly improved. The highest tensile strength was 1281.3 MPa when d=80 mm, which was 30.12 % higher than that without UVA.

Development and experimental validation of a thermo-metallurgical-mechanical model of the laser metal deposition (LMD) process

The current paper presents the development and experimental validation of a thermo-metallurgical-mechanical model for a multi-pass Laser Metal Deposition (LMD) process, with the objective of accurately predicting the resultant constituent phases and residual stresses. The thermal model is calibrated using temperature readings and is shown to accurately capture the transient temperature field and extent of the fusion zone associated with the multi-pass LMD process. The metallurgical model incorporates the kinetics of ongoing solid-state phase transformations (SSPTs) and tempering reactions. The predictions are validated via hardness measurements, demonstrating a very good agreement with the predictions. The developed mechanical model predicts the residual stress field, which is validated using X-ray diffraction measurements, and the comparison also shows a very good agreement between the predictions and measurements. The validated numerical model is then used to explore alternative LMD strategies showing that the choice of deposition strategy can significantly impact resultant constituent phases and residual stresses.

Hybrid Path Generation Method for Multi-Axis Laser Metal Deposition of Overhanging Thin-Walled Structures.

Additive manufacturing has advantages over other traditional manufacturing technologies for the fabrication of complex thin-walled parts. Previous correlation path strategies, when applied to laser metal deposition processes, suffer from contour deposition transboundary and surface "scar" type overstacking. Therefore, this paper proposes a hybrid path generation method for the laser metal deposition process. First, the topological logic of the STL model of the part is restored to reduce redundant calculations at the stage of obtaining the layered contour. Then, the path points are planned on the basis of the offset contours in a helical upward trend to form a globally continuous composite path in space considering the melt channel width. Finally, vectors that adaptively fit to the model surface are generated for the path points as tool orientations and they are optimized by smoothing the rotation angles. The results of experiments conducted on a multi-axis machine equipped with a laser metal deposition module show that the path generated by the proposed method is not only capable of thin-walled structures with overhanging and curved surface features but also improves the surface imperfections of the part due to sudden changes in the angle of rotation while ensuring the boundary dimensions.

Comparative study of Ti-6.5Al-2Zr-1Mo-1V (TA15) alloy fabricated by selective laser melting and laser metal deposition

In the present study, Ti-6.5Al-2Zr-1Mo-1V (TA15) alloy, one of the widely used near-α titanium alloys in the field of aeronautical and astronautical, was fabricated by two lasers additive manufacturing technologies, namely selective laser melting (SLM) and laser metal deposition (LMD). Microstructure, mechanical property, productivity, and forming cost of fabricated TA15 samples by these two processes were compared systematically. The results showed that the microstructure of the SLM-ed and LMD-ed samples exhibited differences in terms of crystallographic orientations, grain boundaries, and grain sizes, which was mainly attributed to the distinct thermal histories associated with each process. Such differences resulted in the LMD-ed sample presenting anisotropy, lower tensile strength, and higher elongation compared to the SLM-ed sample. Cost analysis indicated that the forming cost per unit volume of the LMD-ed sample was about half that of the SLM-ed sample. This difference was primally due to the higher productivity of the LMD process (226.1 cm3/h) compared to the SLM process (8.8 cm3/h), as well as the lower power cost of the powder materials (60 vs. 100 $/kg). Furthermore, the forming maximum volume of the LMD process (∼30.38 m3) was about 28 times than that of the SLM process (∼1.08 m3). In conclusion, this study provides a detailed comparison between SLM-ed and LMD-ed TA15 samples. The findings can act as a reference for selecting optimized fabrication methods for practical industrial applications, taking into consideration specific mechanical properties, forming size, and cost requirements.

Welding of additive manufacturing AlSi10Mg alloys using a laser metal deposition process with different heat inputs

Welding of additive manufacturing AlSi10Mg alloys using a laser metal deposition process with different heat inputs

Experimental study of SS316L, Inconel 625, and SS316L-IN625 functionally graded material produced by direct laser metal deposition process

Three types of walls were produced by the direct laser metal deposition (DLMD) process; SS316L, Inconel 625 (IN625), and SS316L-Inconel 625 FGM. The thin walls were deposited on an AISI 4130 austenitic steel substrate in five layers with a length of 2 cm. The solidification behavior, secondary dendrite arm spacing (SADS) value, chemical composition, and hardness of samples were studied. Microstructures were evaluated using optical microscopy (OM) images, scanning electron microscopy (SEM), EDS Line, EDAX, and Map analyses. OM and SEM images showed an acceptable bonding between the layers in all samples. The main solidification was equiaxed dendritic and columnar dendritic in most parts. The growth of dendrites was perpendicular to the substrate. Some dendrites grew epitaxially at the interface of two sequential layers. The standard deviation of SDAS value for SS316L, IN625, and SS316L-IN625 FGM was 0.63, 0.71, and 0.73, respectively. The lowest value of SDAS was obtained in layer one, while the highest value was obtained in layer five of the thin walls. The average SDAS values for SS316L, IN625, and SS316L-IN625 FGM were 4.40, 4.53, and 4.76 µm, respectively. Therefore, the difference between the SDAS values was not significant. EDAX and Map analyses showed that the segregation of Nb and Mo to the dendritic boundary and the formation of eutectic, secondary phases, and brittle Laves phases have occurred. Additionally, the segregation of Nb and Mo to the dendritic boundary in the SS316L-IN625 FGM sample was higher than SS316L and IN625 samples. The microhardness values oscillated significantly and decreased by moving away from the substrate (in the build direction). The microhardness values of different points of the SS316L-IN625 FGM walls were in the range of 218–278 HV. EDS line scan, microstructure, and microhardness analyses indicated the successful fabrication of the SS316L-IN625 FGM by the DLMD process.

A review of energy efficiency and Machine learning analysis for additive manufacturing of direct laser metal deposition

Additive Manufacturing (AM) is an innovative industrial process that utilizes layering of materials to create unique products with an unprecedented level of flexibility. To maximize the benefits of AM, it is crucial to understand the precise utilization of laser energy. This review provides a concise overview of the Directed Laser Metal Deposition (DLMD) process, which includes an analysis of input parameters and the effective use of laser power, along with the impact of laser synchronous preheating processes. Various input parameters such as travel speed, hatch spacing, powder feed rate, and the standard of distance influence the calculation of volumetric energy density (VED). VED is important for Clad bed geometry, including dilution (D), height (H), width (W) of AM wall, and clad bead stability (ΔH). In the field of manufacturing, Machine Learning (ML) is a commonly used subset of Artificial Intelligence (AI) to improve the quality of processes, expedite production, and reduce costs. Specifically, in Metal Additive Manufacturing (MAM), ML techniques are leveraged to optimize various process parameters, resulting in the production of high-quality, defect-free products. This review provides a detailed explanation of the step-by-step implementation process of ML and its classification within a fundamental structure.

Experimental and Computational Thermal Analysis of Ti-Based Alloy Produced by Laser Metal Deposition Technique

AbstractA Ti-Fe-Si-Cr-Nb alloy was fabricated using laser metal deposition (LMD) technique. The laser power and scanning speed were varied during fabrication to optimize the processing parameters. The thermal behavior during LMD processing was modeled and simulated by means of COMSOL Multiphysics 6.0 software. The samples produced were characterized using an optical microscope, X-ray diffractometer, and scanning electron microscope coupled with energy dispersive spectroscopy. The microhardness and wear behavior of the alloy were tested using a diamond indenter and ball-on-disk wear machine. The results obtained showed that the alloys exhibited similar dendritic microstructure for all processing parameters. The formation of cracks and pores were evident mainly in samples that were produced at high scanning speed and low laser power. A decrease in microhardness was noticed when the laser power was increased, while an increase in scanning speed yielded samples with high microhardness values. The alloy showed good tribological behavior, but no clear relationship between the wear resistance of the alloy and the variation of the laser processing parameters could be established.

Wear and Corrosion Resistant Eutectic High-Entropy Alloy Al0.3CoCrFeNiMo0.75 Produced by Laser Metal Deposition and Spark-Plasma Sintering

Eutectic high-entropy alloys (EHEAs) with a fine-lamellar structure and homogenous property profile are of particular interest for wear and corrosion protection coatings. High cooling rates in the laser metal deposition (LMD) process can induce microstructure refinement and allow the formation of a supersaturated solid solution in EHEAs. A subsequent solution annealing can create the equilibrium state. In the present study, LMD coatings with an ultrafine-grained Widmanstätten structure were produced from the EHEA Al0.3CoCrFeNiMo0.75 gas atomized powder. High cooling rates during deposition led to a supersaturated solid solution with face-centered cubic (FCC) structure. The LMD coating exhibits the highest average hardness of 734 HV0.5, which drops to approx. 200 HV0.5 due to an increased microstructural domain size after heat treatment. Under oscillating wear, the formation of oxidized wear debris promotes material removal in the heat-treated condition. Corrosion tests reveal a deterioration of the passivation behavior. LMD processes exhibit great potential to create supersaturated solid solutions with refined structure in EHEAs to enhance the property profile.

Adaptive powder nozzle setup for enhanced efficiency in laser metal deposition

Laser metal deposition (LMD) is a blown powder process used for the additive manufacturing of large and/or complex parts. The laser spot size is determined by the fiber optic cable and the imaging ratio of the process optics. Spot sizes typically used in LMD can range from 200 μm to several millimeters, whereby zoom optics can be employed to change the laser spot focus within seconds during the process. However, industrial powder nozzles are still static in terms of powder spot size. Changing the powder spot size in line with the laser spot size could ensure the favorable dual outcome of time savings when printing large volumes while also generating fine near-net-shape features. To help overcome the current limitations in the LMD process, this work examines an adaptive powder nozzle setup. In this discrete coaxial layout of three single lateral powder injectors, the individual powder injectors can be adjusted closer to or further from the process to, respectively, dilate or shrink the powder stream focus. Different inner diameters of powder injectors are hereby examined. The resulting powder propagation behavior is characterized for different setups of the single powder nozzles. Single beads are welded with different nozzle setups for fine and coarse powder spots, while the laser spot size is changed accordingly using zoom optics. The laser power is a closed-loop controlled by a two-color pyrometer to achieve comparative process temperatures. The single beads are evaluated with regard to their geometry. High-speed imaging provides supplementary information on weld bead generation.

Off-axis monitoring of the melt pool spatial information in Laser Metal Deposition process

Laser Metal Deposition (LMD) is one of the most promising Additive Manufacturing (AM) technologies for the fabrication, coating and repair of metal components. Although, due to the high number of factors influencing the process, defects may arise, as geometrical and dimensional inaccuracies, high residual stresses and internal voids, with effects on the quality and the mechanical performances of the produced parts. Thus, the need for in-process monitoring systems capable of timely detecting the onset of defects and process anomalies emerged.In this work, an in-process monitoring system suitable for LMD was presented. It consisted of an industrial CMOS camera placed in the LMD machine chamber and set for the acquisition of images showing the melt pool area. Through the use of properly developed image processing algorithms, the monitoring system was capable to extract in-process the melt pool 2D spatial coordinates and to depict the geometry of the fabricated samples. Moreover, specific indexes related to the deposited height were computed in order to evaluate the quality of the process/product. The potentiality of such monitoring method lies in the simplicity of the equipment, and, mostly, in the possibility of monitoring the spatial evolution of the melt pool without interrupting the process and enabling, eventually, a further control of the LMD process. The monitoring system was tested on two 316L thin-walled components and results were validated by comparing the data obtained from the monitoring with a consolidated post-process 3D scanning method.