Demonstration of array eddy current technology for real-time monitoring of laser powder bed fusion additive manufacturing process

Evgueni Todorov; Paul Boulware; Kingsley Gaah

doi:10.1117/12.2297511

27 March 2018 Demonstration of array eddy current technology for real-time monitoring of laser powder bed fusion additive manufacturing process

Evgueni Todorov, Paul Boulware, Kingsley Gaah

Author Affiliations +

Proceedings Volume 10599, Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XII; 1059913 (2018) https://doi.org/10.1117/12.2297511
Event: SPIE Smart Structures and Materials + Nondestructive Evaluation and Health Monitoring, 2018, Denver, Colorado, United States

Abstract

Nondestructive evaluation (NDE) at various fabrication stages is required to assure quality of feedstock and solid builds. Industry efforts are shifting towards solutions that can provide real-time monitoring of additive manufacturing (AM) fabrication process layer-by-layer while the component is being built to reduce or eliminate dependence on post-process inspection. Array eddy current (AEC), electromagnetic NDE technique was developed and implemented to directly scan the component without physical contact with the powder and fused layer surfaces at elevated temperatures inside a LPBF chamber. The technique can detect discontinuities, surface irregularities, and undesirable metallurgical phase transformations in magnetic and nonmagnetic conductive materials used for laser fusion. The AEC hardware and software were integrated with the L-PBF test bed. Two layer-by-layer tests of Inconel 625 coupons with AM built discontinuities and lack of fusion were conducted inside the L-PBF chamber. The AEC technology demonstrated excellent sensitivity to seeded, natural surface, and near-surface-embedded discontinuities, while also detecting surface topography. The data was acquired and imaged in a layer-by-layer sequence demonstrating the real-time monitoring capabilities of this new technology.

Citation Download Citation

Evgueni Todorov, Paul Boulware, and Kingsley Gaah "Demonstration of array eddy current technology for real-time monitoring of laser powder bed fusion additive manufacturing process", Proc. SPIE 10599, Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XII, 1059913 (27 March 2018); https://doi.org/10.1117/12.2297511

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