Flaw detection in powder bed fusion using optical imaging

Mostafa Abdelrahman, Edward William Reutzel, Abdalla Ramadan Nassar, Thomas L. Starr

Research output: Contribution to journalArticle

20 Citations (Scopus)

Abstract

Lack-of-fusion flaws can occur in powder bed fusion (PBF) additive manufacturing of metal components. This paper demonstrates a method for detecting such flaws by monitoring the fabrication of every layer before and after laser scanning with high resolution optical imaging. A binary template is created from the sliced 3D model of the part. Using this template the optical image data is indexed to the part geometry. The indexed image data is used to detect anomalies in the powder layer before laser scanning and in the solidified material after scanning. Lack-of-fusion defects are identified from optical data by correlating multiple images with different lighting conditions and from multiple layers. To test the algorithms intentional defects are created inside a test part at different locations and are successfully detected with a high true positive rate.

Original languageEnglish (US)
Pages (from-to)1-11
Number of pages11
JournalAdditive Manufacturing
Volume15
DOIs
StatePublished - May 1 2017

Fingerprint

Powders
Fusion reactions
Imaging techniques
Defects
Scanning
3D printers
Lasers
Lighting
Metals
Fabrication
Geometry
Monitoring

All Science Journal Classification (ASJC) codes

  • Biomedical Engineering
  • Materials Science(all)
  • Engineering (miscellaneous)
  • Industrial and Manufacturing Engineering

Cite this

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Flaw detection in powder bed fusion using optical imaging. / Abdelrahman, Mostafa; Reutzel, Edward William; Nassar, Abdalla Ramadan; Starr, Thomas L.

In: Additive Manufacturing, Vol. 15, 01.05.2017, p. 1-11.

Research output: Contribution to journalArticle

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