Parametric analysis of SLM using comprehensive optical monitoring

Abstract

Purpose

This paper aims to propose methods for on-line monitoring and process quality assurance of Selective Laser Melting (SLM) technology as a competitive advantage to enhance its implementation into modern manufacturing industry.

Design/methodology/approach

Monitoring of thermal emission from the laser impact zone was carried out by an originally developed pyrometer and a charge-coupled device (CCD) camera which were integrated with the optical system of the PHENIX PM-100 machine. Experiments are performed with variation of the basic process parameters such as powder layer thickness (0-120 μm), hatch distance (60-1,000 μm) and fabrication strategy (the so-called “one-zone” and “two-zone”).

Findings

The pyrometer signal from the laser impact zone and the 2D temperature mapping from HAZ are rather sensible to variation of high-temperature phenomena during powder consolidation imposed by variation of the operational parameters.

Research limitations/implications

Pyrometer measurements are in arbitrary units. This limitation is due to the difficulty to integrate diagnostic tools into the optical system of a commercial SLM machine.

Practical implications

Enhancement of SLM process stability and efficiency through comprehensive optical diagnostics and on-line control.

Originality/value

High-temperature phenomena in SLM were monitored coaxially with the laser beam for variation of several operational parameters.

Citation

Doubenskaia, M., Grigoriev, S., Zhirnov, I. and Smurov, I. (2016), "Parametric analysis of SLM using comprehensive optical monitoring", Rapid Prototyping Journal, Vol. 22 No. 1, pp. 40-50. https://doi.org/10.1108/RPJ-04-2014-0046