Comparison of in-situ near infrared melt pool imagery to optical microscopy measurements

Joseph N. Zalameda; Samuel J. Hocker; Wesley A. Tayon; Joshua M. Fody; Brodan M. Richter

doi:10.1117/12.2621037

27 May 2022 Comparison of in-situ near infrared melt pool imagery to optical microscopy measurements

Joseph N. Zalameda, Samuel J. Hocker, Wesley A. Tayon, Joshua M. Fody, Brodan M. Richter

Proceedings Volume 12109, Thermosense: Thermal Infrared Applications XLIV; 1210902 (2022) https://doi.org/10.1117/12.2621037
Event: SPIE Defense + Commercial Sensing, 2022, Orlando, Florida, United States

Abstract

Additive manufacturing (AM) is a rapidly growing technology. An area of major importance is the integrity and repeatability of AM parts. The goal is to reduce obstacles to certify AM built parts to allow for use in critical aerospace applications. In-situ nondestructive evaluation sensors can be used for build assessment and can potentially play a key role in certifying AM parts. For example, melt pool features are understood to have a strong correlation to microstructural defects and the use of a near infrared (NIR) camera can be used to record the melt pool, cooling areas, and temperature gradients during the build. This work explores the use of a low cost NIR camera to obtain single line track imagery of the Ti-6Al-4V melt pools for various processing parameters. The NIR camera is radiometrically calibrated and configured in-line with the laser source to obtain high resolution imagery of the melt pool shape and dynamics. The challenge to measure melt pool shapes is to identify the transition points between the metal solid to liquid phase. Factors for melt pool measurements such as thermal camera pixel resolution, surface emissivity, and blurring are discussed. Lastly, the melt pool imagery are compared to optical microscopy measurements for validation.

Conference Presentation

Citation Download Citation

Joseph N. Zalameda, Samuel J. Hocker, Wesley A. Tayon, Joshua M. Fody, and Brodan M. Richter "Comparison of in-situ near infrared melt pool imagery to optical microscopy measurements", Proc. SPIE 12109, Thermosense: Thermal Infrared Applications XLIV, 1210902 (27 May 2022); https://doi.org/10.1117/12.2621037

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