Illumination and image processing for real-time control of directed energy deposition additive manufacturing

Research output: Contribution to conferencePaperpeer-review

6 Scopus citations

Abstract

This paper describes the optical setup and image processing required to estimate melt-pool width and build height for real-time control of melt-pool geometry in directed energy deposition additive manufacturing. To overcome optical interference from plasma emissions and laser interactions, the melt-zone is imaged using laser illumination. A single camera, fixed to the processing laser, views the laser interaction zone and provides images for estimating melt-zone width and build height. Using a bandpass filter and a single aspheric lens, the camera system provides sufficient magnification and depth of field to achieve a 1-mil (25.4 µm) resolution. Maintaining melt-zone geometry within desired tolerances requires an image acquisition and processing rate on the order of 100 frames per second. This bandwidth is achieved by a Camera Link camera and field-programmable gate array that implements algorithms for estimating melt-pool width and build height. The design and experimental verification of the camera, illumination, and processing systems are discussed.

Original languageEnglish (US)
Pages1479-1486
Number of pages8
StatePublished - 2016
Event27th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2016 - Austin, United States
Duration: Aug 8 2016Aug 10 2016

Conference

Conference27th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2016
CountryUnited States
CityAustin
Period8/8/168/10/16

All Science Journal Classification (ASJC) codes

  • Surfaces and Interfaces
  • Surfaces, Coatings and Films

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