TY - JOUR A1 - Moskovchenko, A. I. A1 - Vavilov, V. P. A1 - Bernegger, Raphael A1 - Maierhofer, Christiane A1 - Chulkov, A. O. T1 - Detecting Delaminations in Semitransparent Glass Fiber Composite by Using Pulsed Infrared Thermography N2 - Thanks to its good strength/mass ratio, a glass fibre reinforced plastic (GFRP) composite is a common material widely used in aviation, power production, automotive and other industries. In its turn, active infrared (IR) nondestructive testing (NDT) is a common inspection technique for detecting and characterizing structural defects in GFRP. Materials to be tested are typically subjected to optical heating which is supposed to occur on the material surface. However, GFRP composite is semitransparent for optical radiation of both visual and IR spectral bands. Correspondingly, the inspection process represents a certain combination of both optical and thermal phenomena. Therefore, the known characterization algorithms based on pure heat diffusion cannot be applied to semi-transparent materials. In this study, the phenomenon of GFRP semi-transparency has been investigated numerically and experimentally in application to thermal NDT. Both Xenon flash tubes and a laser have been used for thermal stimulation of opaque and semi-transparent test objects. It has been shown that the Penetration of optical heating radiation into composite reduces detectability of shallower defects, and the signal-to-noise ratio can be enhanced by applying the technique of thermographic signal reconstruction (TSR). In the inspection of the semi-transparent GFRP composite, the most efficient has been the laser heating followed by the TSR data processing. The perspectives of defect characterization of semi-transparent materials by using laser heating are discussed. A neural network has been used as a candidate tool for evaluating defect depth in composite materials, but its training should be performed in identical with testing conditions. KW - Infrared thermography KW - Thermal testing KW - GFRP KW - Semi-transparent composite KW - Laser heating PY - 2020 U6 - https://doi.org/10.1007/s10921-020-00717-x VL - 39 SP - 69 PB - Springer Science+Business Media, LLC, part of Springer Nature 2020 AN - OPUS4-51179 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Mohr, Gunther A1 - Nowakowski, Susanna A1 - Altenburg, Simon A1 - Maierhofer, Christiane A1 - Hilgenberg, Kai T1 - Experimental Determination of the Emissivity of Powder Layers and Bulk Material in Laser Powder Bed Fusion Using Infrared Thermography and Thermocouples N2 - Recording the temperature distribution of the layer under construction during laser powder bed fusion (L-PBF) is of utmost interest for a deep process understanding as well as for quality assurance and in situ monitoring means. While having a notable number of thermal monitoring approaches in additive manufacturing (AM), attempts at temperature calibration and emissivity determination are relatively rare. This study aims for the experimental temperature adjustment of an off-axis infrared (IR) thermography setup used for in situ thermal data acquisition in L-PBF processes. The temperature adjustment was conducted by means of the so-called contact method using thermocouples at two different surface conditions and two different materials: AISI 316L L-PBF bulk surface, AISI 316L powder surface, and IN718 powder surface. The apparent emissivity values for the particular setup were determined. For the first time, also corrected, closer to real emissivity values of the bulk or powder surface condition are published. In the temperature region from approximately 150 °C to 580 °C, the corrected emissivity was determined in a range from 0.2 to 0.25 for a 316L L-PBF bulk surface, in a range from 0.37 to 0.45 for 316L powder layer, and in a range from 0.37 to 0.4 for IN718 powder layer. KW - Emisssivity KW - Laser Powder Bed Fusion (L-PBF) KW - Selective Laser Melting (SLM) KW - Additive Manufacturing (AM) KW - Process monitoring KW - Infrared thermography PY - 2020 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-516148 VL - 10 IS - 11 SP - 1546 PB - MDPI CY - Basel, Schweiz AN - OPUS4-51614 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Bernegger, Raphael A1 - Maierhofer, Christiane A1 - Altenburg, Simon T1 - Quantification of delaminations in semitransparent solids using pulsed thermography and mathematical 1D models N2 - Material defects in fiber reinforced polymers such as delaminations can rapidly degrade the material properties or can lead to the failure of a component. Pulse thermography (PT) has proven to be a valuable tool to identify and quantify such defects in opaque materials. However, quantification of delaminations within semitransparent materials is extremely challenging. We present an approach to quantify delaminations within materials being semitransparent within the wavelength ranges of the optical excitation sources as well as of the infrared (IR) camera. PT experimental data of a glass fiber reinforced polymer with a real delamination within the material were reconstructed by one dimensional (1D) mathematical models. These models describe the heat diffusion within the material and consider semitransparency to the excitation source as well to the IR camera, thermal losses at the samples surfaces and a thermal contact resistance between the two layers describing the delamination. By fitting the models to the PT data, we were able to determine the depth of the delamination very accurately. Additionally, we analyzed synthetic PT data from a 2D simulation with our 1D-models to show how the thermal contact resistance is influenced by lateral heat flow within the material. KW - Pulsed thermography KW - Quantification KW - Numerical simulation KW - Analytical model KW - Semitransparent KW - GFRP KW - Delamination PY - 2020 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-505766 VL - 41 IS - 5 SP - Article number: 67 PB - Springer AN - OPUS4-50576 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Altenburg, Simon A1 - Straße, Anne A1 - Gumenyuk, Andrey A1 - Maierhofer, Christiane T1 - In-situ monitoring of a laser metal deposition (LMD) process: comparison of MWIR, SWIR and high-speed NIR thermography N2 - Additive manufacturing offers a range of novel applications. However, the manufacturing process is complex and the production of almost defect-free parts with high reliability and durability is still a challenge. Thermography is a valuable tool for process surveillance, especially in metal additive manufacturing processes. The high process temperatures allow one to use cameras usually operating in the visible spectral range. Here, we compare the results of measurements during the manufacturing process of a commercial laser metal deposition setup using a mid wavelength infrared camera with those from a short wavelength infrared camera and those from a visual spectrum high-speed camera with band pass filter in the near infrared range. KW - Additive Manufacturing KW - Process monitoring KW - Thermography KW - LMD KW - Metal KW - MWIR KW - SWIR KW - NIR PY - 2020 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-516318 VL - 19 IS - 2 SP - 97 EP - 114 PB - Taylor & Francis Group CY - London, UK AN - OPUS4-51631 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Maierhofer, Christiane A1 - Altenburg, Simon A1 - Scheuschner, Nils T1 - Prozessüberwachung in der additiven Fertigung von Metallen - das Projekt ProMoAM N2 - Prozessüberwachung in der additiven Fertigung von Metallen - das Projekt ProMoAM. In diesem Vortrag wird das gesamte Projekt vorgestellt. Dabei wird auf die Thermografie im LMD und L-PBF Prozess näher eingegangen. Hierbei werden sowohl stationäre als auch mit bewegte Systeme vorgestellt. T2 - Webinar: Inline-Messtechnik und –Prozessüberwachung CY - Online meeting DA - 01.07.2020 KW - Pulverbettverfahren KW - Laser Metal Deposition KW - Thermografie KW - Optische Tomografie PY - 2020 UR - https://quality-engineering.industrie.de/webinarreihe-additive-verfahren/#Inline-Messtechnik AN - OPUS4-50962 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Altenburg, Simon A1 - Scheuschner, Nils A1 - Maierhofer, Christiane A1 - Mohr, Gunther A1 - Hilgenberg, Kai T1 - Thermography in laser powder bed fusion of metals: time over threshold as feasible feature in thermographic data N2 - Thermography is one on the most promising techniques for in-situ monitoring of metal additive manufacturing processes. Especially in laser powder bed fusion processes, the high process dynamics and the strong focus of the laser beam cause a very complex thermal history within the produced specimens, such as multiple heating cycles within single layer expositions. This complicates data interpretation, e.g., in terms of cooling rates. A quantity that is easily calculated is the time a specific area of the specimen is at a temperature above a chosen threshold value (TOT). Here, we discuss variations occurring in time-over-threshold-maps during manufacturing of an almost defect free cuboid specimen. T2 - 15th Quantitative InfraRed Thermography conference CY - Online meeting DA - 21.09.2020 KW - Additive Manufacturing KW - Process monitoring KW - Thermography KW - L-PBF KW - Time over threshold PY - 2020 U6 - https://doi.org/10.21611/qirt.2020.005 SP - 1 EP - 5 PB - QIRT Council CY - Quebec, Canada AN - OPUS4-52014 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Mohr, Gunther A1 - Altenburg, Simon A1 - Ulbricht, Alexander A1 - Heinrich, Ph. A1 - Baum, D. A1 - Maierhofer, Christiane A1 - Hilgenberg, Kai T1 - In-Situ Defect Detection in Laser Powder Bed Fusion by Using Thermography and Optical Tomography—Comparison to Computed Tomography N2 - Among additive manufacturing (AM) technologies, the laser powder bed fusion (L-PBF) is one of the most important technologies to produce metallic components. The layer-wise build-up of components and the complex process conditions increase the probability of the occurrence of defects. However, due to the iterative nature of its manufacturing process and in contrast to conventional manufacturing technologies such as casting, L-PBF offers unique opportunities for in-situ monitoring. In this study, two cameras were successfully tested simultaneously as a machine manufacturer independent process monitoring setup: a high-frequency infrared camera and a camera for long time exposure, working in the visible and infrared spectrum and equipped with a near infrared filter. An AISI 316L stainless steel specimen with integrated artificial defects has been monitored during the build. The acquired camera data was compared to data obtained by computed tomography. A promising and easy to use examination method for data analysis was developed and correlations between measured signals and defects were identified. Moreover, sources of possible data misinterpretation were specified. Lastly, attempts for automatic data analysis by data Integration are presented. KW - Laser powder bed fusion (L-PBF) KW - Selective laser melting (SLM) KW - Additive manufacturing (AM) KW - Process monitoring KW - Infrared thermography KW - Optical tomography KW - Computed tomography (CT) KW - Data fusion KW - Lack-of-fusion PY - 2020 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-502417 VL - 10 IS - 1 SP - 103 PB - MDPI CY - Basel, Schweiz AN - OPUS4-50241 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -