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An airborne laser plasma is suggested as an ambient ion source for mass spectrometry. Its fundamental physical properties, such as an excellent spatial and temporal definition, high electron and ion densities and a high effective cross section in maintaining the plasma, make it a promising candidate for future applications. For deeper insights into the plasma properties, the optical plasma emission is examined and compared to mass spectra. The results show a seemingly contradictory behavior, since the emitted light reports the plasma to almost entirely consist of hot elemental ions, while the corresponding mass spectra exhibit the formation of intact molecular species. Further experiments, including time- resolved shadowgraphy, spatially resolved mass spectrometry, as well as flow-dependent emission spectroscopy and mass spectrometry, suggest the analyte molecules to be formed in the cold plasma vicinity upon interaction with reactive species formed inside the hot plasma center. Spatial separation is maintained by concentrically expanding pressure waves, inducing a strong unidirectional diffusion. The accompanying rarefaction inside the plasma center can be compensated by a gas stream application. This replenishing results in a strong increase in emission brightness, in local reactive species concentration, and eventually in direct mass spectrometric sensitivity. To determine the analytical performance of the new technique, a comparison with an atmospheric pressure chemical ionization (APCI) source was conducted. Two kitchen herbs, namely, spearmint and basil, were analyzed without any sample pretreatment. The presented results demonstrate a considerably higher sensitivity of the presented laser-spark ionization technique.
Optical elemental analysis in the gas phase typically relies on electrically driven plasmas. As an alternative approach, laser-induced plasmas (LIPs) have been suggested but have so far been only scarcely used.
Here, a novel signal enhancement strategy for laser-based airborne plasma optical Emission spectroscopy for gas phase analytics is presented. In contrast to an electrically driven plasma, in the laser-induced analogue dynamic matter transport equilibrium builds up. The latter results in a rarefied density regime in the plasma core itself, surrounded by an area of compressed matter. The central rarefaction leads to a decrease in plasma intensity and analyte number density, both of which are detrimental for analytical purposes. Since the repetitive ignition of LIPs is a transient process, a restoration of the former gaseous medium by other dynamically equilibrated diffusion processes would be favourable. The presented combination of an airborne LIP and an ultrasonic acoustic resonator yields a fourfold signal enhancement while the Background contribution of ubiquitous air is at the same time effectively suppressed. Since the entire enhancement effect occurs without contact, no additional sources for abrasive sample contamination are introduced.
A magnetically stabilized DC arc device, designed for operation with OES spectrometers was used to determine the elements Ag, Al, B, Ba, Be, Ca, Co, Cr, Cu, Fe, Ga, In, K, Li, Mg, Mn, Mo, Na, Nb, Ni, Si, Sn, Sr, Ti, V, Zr at trace levels of some μg kg−1 up to some 10 mg kg−1 in graphite powders. The coil for the generation of the homogeneous magnetic field was placed outside the closed arc chamber. The time programs of variable current strengths of the magnetic coil (up to 6 A) and of the arc (up to 17 A) which was burning in air were computer controlled. Halogenating gases (mainly CCl2F2, alternatively SF6 and NF3) were used as chemical modifiers to allow an effective release of the carbide forming trace elements. The mass flow controlled modifier gas was led through a special carrier electrode near the arc plasma. The emission radiation was guided by an optical fiber alternatively into two different ICP spectrometers in which the ICP torches were removed. The synergistic interaction of the magnetic field with the halogenating modifier gases resulted in a significant improvement in the analytical performance of the optimized analytical method. All our results for 22 trace elements were in good agreement with the means of an inter-laboratory comparison by BAM for certification of a pure graphite powder material; this holds also for our results for two other graphite materials. The optimized method showed an analytical performance suitable for comprehensive trace analysis of pure graphite. The instrumentation could be integrated into modern DC arc emission spectrometers to improve their analytical capabilities substantially.
Additive manufacturing by laser metal deposition (LMD) requires continuous online monitoring to ensure quality of printed parts. Optical emission spectroscopy (OES) is proposed for the online detection of printing defects by monitoring minute variations in the temperature of a printed spot during laser scan. A two-lens optical system is attached to a moving laser head and focused on a molten pool created on a substrate during LMD. The light emitted by the pool is collected by an ultraviolet–visible (UV–vis) spectrometer and processed.
Two metrics are used to monitor variations in the surface temperature: the spectrally integrated emission intensity and correlation coefficient. The variations in the temperature are introduced by artificial defects, shallow grooves, and holes of various widths and diameters carved on a substrate surface. The metrics show sufficient sensitivity for revealing the surface defects, except for the smallest
holes with an under-millimeter diameter. Additionally, numeric simulations are carried out for the detection of emission in the UV–vis and near-infrared (NIR) spectral ranges at various surface temperatures. It is concluded that both the metrics perform better in the NIR range. In general, this work demonstrates that spectrally resolved OES suits well for monitoring surface defects during 3D metal
printing.
Laser metal deposition is a rapidly evolving method for additive manufacturing that combines high performance and simplified production routine. Quality of production depends on an instrumental design and operational parameters, which require constant control during the process. In this work, feasibility of using optical spectroscopy as a control method is studied via modeling and experimentally. A simplified thermal model is developed based on the time-dependent diffusion-conduction heat equation and geometrical light collection into detection optics. Intense light emitted by a laser-heated spot moving across a sample surface is collected and processed to yield the temperature and other temperature-related parameters. In the presence of surface defects, the temperature field is distorted in a specific manner that depends on shape and size of the defect. Optical signals produced by such the distorted temperature fields are simulated and verified experimentally using a 3D metal printer and a sample with artificially carved defects. Three quantities are tested as possible metrics for monitoring the process: temperature, integral intensity, and correlation coefficient. The shapes of the simulated signals qualitatively agree with the experimental signals; this allows for a cautious inference that optical spectroscopy can detect surface defects and, possibly, predict their characters, e.g., inner or protruding.
Laser metal deposition is a rapidly evolving method for additive manufacturing that combines high performance and simplified production routine. Quality of production depends on instrumental design and operational parameters that require constant control during the process. In this work, feasibility of using optical spectroscopy as a control method is studied via modeling and experimentally. A simplified thermal model is developed based on the time-dependent diffusion-conduction heat equation and geometrical light collection into detection optics. Intense light emitted by a laser-heated spot moving across a sample surface is collected and processed to yield the temperature and other temperature-related parameters. In a presence of surface defects the temperature field is distorted in a specific manner that depends on a shape and size of the defect. Optical signals produced by such the distorted temperature fields are simulated and verified experimentally using a 3D metal printer and a sample with artificially carved defects. Three quantities are tested as possible metrics for process monitoring: temperature, integral intensity, and correlation coefficient. The shapes of the simulated signals qualitatively agree with the experimental signals; this allows a cautious inference that optical spectroscopy is capable of detecting a defect and, possibly, predicting its character, e.g. inner or protruding.
For metal-based additive manufacturing, sensors and measuring systems for monitoring of the energy source, the build volume, the melt pool and the component geometry are already commercially available. Further methods of optics, spectroscopy and non-destructive testing are described in the literature as suitable for in-situ application, but there are only a few reports on practical implementations.
Therefore, a new BAM project aims to develop process monitoring methods for the in-situ evaluation of the quality of additively manufactured metal components. In addition to passive and active thermography, this includes optical tomography, optical emission and absorption spectroscopy, eddy current testing, laminography, X-ray backscattering and photoacoustic methods. These methods are used in additive manufacturing systems for selective laser melting, laser metal deposition and wire arc additive manufacturing. To handle the sometimes huge amounts of data, algorithms for efficient preprocessing are developed and characteristics of the in-situ data are extracted and correlated to defects and inhomogeneities, which are determined using reference methods such as computer tomography and metallography. This process monitoring and fusion of data of different measurement techniques should result in a significant reduction of costly and time-consuming, destructive or non-destructive tests after the production of the component and at the same time reduce the production of scrap.
Here, first results of simultaneous measurements of optical emission spectroscopy and thermography during the laser metal deposition process using 316L as building material are presented. Temperature values are extracted from spectroscopic data by fitting of blackbody emission spectra to the experimental data and compared with results from a thermographic camera. Measurements with and without powder flow reveal significant differences between welding at a pristine metal surface and previously melted positions on the build plate, illustrating the significant influence of the partial oxidation of the surface during the first welding process on subsequent welding. The measurement equipment can either be mounted stationary or following the laser path. While first results were obtained in the stationary mode, future applications for online monitoring of the build of whole parts in the mobile mode are planned.
This research was funded by BAM within the focus area Material.