In-process thermal imaging of the electron beam freeform fabrication process

Karen M. Taminger; Christopher S. Domack; Joseph N. Zalameda; Brian L. Taminger; Robert A. Hafley; Eric R. Burke

doi:10.1117/12.2222439

11 May 2016 In-process thermal imaging of the electron beam freeform fabrication process

Karen M. Taminger, Christopher S. Domack, Joseph N. Zalameda, Brian L. Taminger, Robert A. Hafley, Eric R. Burke

Proceedings Volume 9861, Thermosense: Thermal Infrared Applications XXXVIII; 986102 (2016) https://doi.org/10.1117/12.2222439
Event: SPIE Commercial + Scientific Sensing and Imaging, 2016, Baltimore, MD, United States

Abstract

Researchers at NASA Langley Research Center have been developing the Electron Beam Freeform Fabrication (EBF³) metal additive manufacturing process for the past 15 years. In this process, an electron beam is used as a heat source to create a small molten pool on a substrate into which wire is fed. The electron beam and wire feed assembly are translated with respect to the substrate to follow a predetermined tool path. This process is repeated in a layer-wise fashion to fabricate metal structural components. In-process imaging has been integrated into the EBF³ system using a near-infrared (NIR) camera. The images are processed to provide thermal and spatial measurements that have been incorporated into a closed-loop control system to maintain consistent thermal conditions throughout the build. Other information in the thermal images is being used to assess quality in real time by detecting flaws in prior layers of the deposit. NIR camera incorporation into the system has improved the consistency of the deposited material and provides the potential for real-time flaw detection which, ultimately, could lead to the manufacture of better, more reliable components using this additive manufacturing process.

Citation Download Citation

Karen M. Taminger, Christopher S. Domack, Joseph N. Zalameda, Brian L. Taminger, Robert A. Hafley, and Eric R. Burke "In-process thermal imaging of the electron beam freeform fabrication process", Proc. SPIE 9861, Thermosense: Thermal Infrared Applications XXXVIII, 986102 (11 May 2016); https://doi.org/10.1117/12.2222439

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