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Online Process Monitoring for Additive Manufacturing Using Eddy Current Testing With Magnetoresistive Sensor Arrays

  • The rising popularity of additive manufacturing processes leads to an increased interest in possibilities and methods for related process monitoring. Such methods ensure improved process quality and increase the understanding of the manufacturing process, which in turn is the basis for stable component quality, e.g., required in the aerospace industry or in the medical sector. For laser powder bed fusion, a handful of process monitoring tools already exist, such as optical tomography, thermography, pyrometry, imaging, or laser power monitoring. Although these tools provide helpful information about the process, more information is required for an accurate in-depth understanding. In this article, advanced approaches in eddy current testing (ET) are combined, such as single wire excitation, magnetoresistive (MR) sensor arrays, and heterodyning to build up a system that can be used for online process monitoring of laser powder bed fusion. In addition to detailed information about theThe rising popularity of additive manufacturing processes leads to an increased interest in possibilities and methods for related process monitoring. Such methods ensure improved process quality and increase the understanding of the manufacturing process, which in turn is the basis for stable component quality, e.g., required in the aerospace industry or in the medical sector. For laser powder bed fusion, a handful of process monitoring tools already exist, such as optical tomography, thermography, pyrometry, imaging, or laser power monitoring. Although these tools provide helpful information about the process, more information is required for an accurate in-depth understanding. In this article, advanced approaches in eddy current testing (ET) are combined, such as single wire excitation, magnetoresistive (MR) sensor arrays, and heterodyning to build up a system that can be used for online process monitoring of laser powder bed fusion. In addition to detailed information about the developed ET system and underlying signal processing, the first results of magnetoresistance-basedonline ET during the laser powder fusion process are presented. While producing a step-shaped cuboid, each layer is tested during recoating. Test results show that not only the contours of the topmost layer are detected but also the contours of previous layers covered by powder. At an excitation frequency of 1 MHz, a penetration depth of approx. 400 μm is obtained. To highlight the possibilities of ET for online process monitoring of laser powder bed fusion, results are compared with postexposure images of the integrated layer control system (LCS).zeige mehrzeige weniger

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Metadaten
Autor*innen:Henrik Ehlers, R. Thewes, Matthias Pelkner
Dokumenttyp:Zeitschriftenartikel
Veröffentlichungsform:Verlagsliteratur
Sprache:Englisch
Titel des übergeordneten Werkes (Englisch):IEEE Sensors Journal
Jahr der Erstveröffentlichung:2022
Organisationseinheit der BAM:8 Zerstörungsfreie Prüfung
8 Zerstörungsfreie Prüfung / 8.4 Akustische und elektromagnetische Verfahren
Veröffentlichende Institution:Bundesanstalt für Materialforschung und -prüfung (BAM)
Verlag:IEEE
Verlagsort:New York, NY
Jahrgang/Band:22
Ausgabe/Heft:20
Erste Seite:19293
Letzte Seite:19300
DDC-Klassifikation:Naturwissenschaften und Mathematik / Chemie / Analytische Chemie
Freie Schlagwörter:Additive manufacturing; Eddy current testing; Giant magneto resistance (GMR); Laser powder bed fusion; Process monitoring
Themenfelder/Aktivitätsfelder der BAM:Chemie und Prozesstechnik
DOI:10.1109/JSEN.2022.3205177
URN:urn:nbn:de:kobv:b43-560881
Verfügbarkeit des Dokuments:Datei für die Öffentlichkeit verfügbar ("Open Access")
Lizenz (Deutsch):License LogoCreative Commons - CC BY - Namensnennung 4.0 International
Datum der Freischaltung:26.10.2022
Referierte Publikation:Ja
Datum der Eintragung als referierte Publikation:07.11.2022
Schriftenreihen ohne Nummerierung:Wissenschaftliche Artikel der BAM
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