Inprocess Detection of Deposition Geometrical Anomalies in LMD-W Using Temperature Signal

Kód výsledku v IS VaVaI

<a href="https://www.isvavai.cz/riv?ss=detail&h=RIV%2F68407700%3A21220%2F24%3A00381223" target="_blank" >RIV/68407700:21220/24:00381223 - isvavai.cz</a>

Výsledek na webu

<a href="https://www.iws.fraunhofer.de/en/events/archive_2024/summer-school.html" target="_blank" >https://www.iws.fraunhofer.de/en/events/archive_2024/summer-school.html</a>

DOI - Digital Object Identifier

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Jazyk výsledku

angličtina

Název v původním jazyce

Inprocess Detection of Deposition Geometrical Anomalies in LMD-W Using Temperature Signal

Popis výsledku v původním jazyce

Additive manufacturing technologies offer a promising method for fabricating components with complex geometries, particularly thin-walled parts made from materials with low machinability, such as those used in the aerospace industry. Ensuring the quality and defect-free production of these parts hinges on the precise selection of technological parameters. However, a significant challenge in the laser metal deposition with wire (LMD-w) process is the accumulation of heat within the component. This heat accumulation can lead to process instability and defect formation when technological parameters are kept constant. Furthermore, the accumulation of energy impacts the geometry of the weld bead, affecting the geometric accuracy of the final part. The objective of this research is to utilise a pyrometer to monitor the stability of the LMD-w process and identify potential defect locations. Additionally, the study investigates the sample geometry at different process temperatures. The process employs a Precitec CoaxPrinter laser head mounted on a robot, integrated with a Metis M322 pyrometer from SenzorTherm. The acquired data are processed using Matlab software. An experiment was carried out to produce a sample size of 40x31x11 mm using two different strategies. The common parameters for both strategies are WFS = 10 mm/s, TS = 500 mm/min, and wire diameter 1.2 mm in 316L stainless steel. Strategy 1 consists of producing the part in halves with constant power P=1300W. After the first half was produced, the part was allowed to cool, and then the second half was produced. Strategy 2 was produced in five parts with decreasing power (1400 W, 1200 W, 1000 W, 950 W, 900 W), with no cooling between these parts. From the temperature record, it was possible to identify defects caused by process instability, which occurred in strategy 1 due to overheating of the part. The actual dimensions of the samples were analysed using a 3D optical scanner. It was found that the sample was wider at the top due to the higher process temperature. Our results indicate that real-time monitoring of temperature using a pyrometer significantly enhances the ability to maintain process stability and detect defects early. Analysis of the weld bead geometry at elevated temperatures reveals critical insights into the effects of heat accumulation on geometric accuracy. These findings underscore the importance of monitoring and temperature control in the LMD-w process to produce high-quality components.

Název v anglickém jazyce

Inprocess Detection of Deposition Geometrical Anomalies in LMD-W Using Temperature Signal

Popis výsledku anglicky

Additive manufacturing technologies offer a promising method for fabricating components with complex geometries, particularly thin-walled parts made from materials with low machinability, such as those used in the aerospace industry. Ensuring the quality and defect-free production of these parts hinges on the precise selection of technological parameters. However, a significant challenge in the laser metal deposition with wire (LMD-w) process is the accumulation of heat within the component. This heat accumulation can lead to process instability and defect formation when technological parameters are kept constant. Furthermore, the accumulation of energy impacts the geometry of the weld bead, affecting the geometric accuracy of the final part. The objective of this research is to utilise a pyrometer to monitor the stability of the LMD-w process and identify potential defect locations. Additionally, the study investigates the sample geometry at different process temperatures. The process employs a Precitec CoaxPrinter laser head mounted on a robot, integrated with a Metis M322 pyrometer from SenzorTherm. The acquired data are processed using Matlab software. An experiment was carried out to produce a sample size of 40x31x11 mm using two different strategies. The common parameters for both strategies are WFS = 10 mm/s, TS = 500 mm/min, and wire diameter 1.2 mm in 316L stainless steel. Strategy 1 consists of producing the part in halves with constant power P=1300W. After the first half was produced, the part was allowed to cool, and then the second half was produced. Strategy 2 was produced in five parts with decreasing power (1400 W, 1200 W, 1000 W, 950 W, 900 W), with no cooling between these parts. From the temperature record, it was possible to identify defects caused by process instability, which occurred in strategy 1 due to overheating of the part. The actual dimensions of the samples were analysed using a 3D optical scanner. It was found that the sample was wider at the top due to the higher process temperature. Our results indicate that real-time monitoring of temperature using a pyrometer significantly enhances the ability to maintain process stability and detect defects early. Analysis of the weld bead geometry at elevated temperatures reveals critical insights into the effects of heat accumulation on geometric accuracy. These findings underscore the importance of monitoring and temperature control in the LMD-w process to produce high-quality components.

Druh

O - Ostatní výsledky

CEP obor

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OECD FORD obor

20302 - Applied mechanics

Projekt

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Návaznosti

S - Specificky vyzkum na vysokych skolach

Rok uplatnění

2024

Kód důvěrnosti údajů

S - Úplné a pravdivé údaje o projektu nepodléhají ochraně podle zvláštních právních předpisů