Review of in-situ process monitoring and in-situ metrology for metal additive manufacturing

Everton, Sarah K.; Hirsch, Matthias; Stravroulakis, Petros; Leach, Richard K.; Clare, Adam T.

Abstract

Lack of assurance of quality with additively manufactured (AM) parts is a key technological barrier that prevents manufacturers from adopting AM technologies, especially for high-value applications where component failure cannot be tolerated. Developments in process control have allowed significant enhancement of AM techniques and marked improvements in surface roughness and material properties, along with a reduction in inter-build variation and the occurrence of embedded material discontinuities. As a result, the exploitation of AM processes continues to accelerate. Unlike established subtractive processes, where in-process monitoring is now commonplace, factory-ready AM processes have not yet incorporated monitoring technologies that allow discontinuities to be detected in process. Researchers have investigated new forms of instrumentation and adaptive approaches which, when integrated, will allow further enhancement to the assurance that can be offered when producing AM components. The state-of-the-art with respect to inspection methodologies compatible with AM processes is explored here. Their suitability for the inspection and identification of typical material discontinuities and failure modes is discussed with the intention of identifying new avenues for research and proposing approaches to integration into future generations of AM systems.

Citation

Everton, S. K., Hirsch, M., Stravroulakis, P., Leach, R. K., & Clare, A. T. (2016). Review of in-situ process monitoring and in-situ metrology for metal additive manufacturing. Materials and Design, 95, 431-445. https://doi.org/10.1016/j.matdes.2016.01.099

• Journal Article Type: Article
• Acceptance Date: Jan 21, 2016
• Publication Date: Apr 5, 2016
• Deposit Date: Feb 29, 2016
• Publicly Available Date: Apr 5, 2016
• Journal: Materials & Design
• Electronic ISSN: 0261-3069
• Publisher: Elsevier
• Peer Reviewed: Peer Reviewed
• Volume: 95
• Pages: 431-445
• DOI: https://doi.org/10.1016/j.matdes.2016.01.099
• Keywords: Process monitoring, additive manufacturing, quality assurance, defect detection
• Public URL: https://nottingham-repository.worktribe.com/output/771844
• Publisher URL: http://www.sciencedirect.com/science/article/pii/S0264127516300995
• Additional Information: This article is maintained by: Elsevier; Article Title: Review of in-situ process monitoring and in-situ metrology for metal additive manufacturing; Journal Title: Materials & Design; CrossRef DOI link to publisher maintained version: https://doi.org/10.1016/j.matdes.2016.01.099; Content Type: article; Copyright: Copyright © 2016 The Authors. Published by Elsevier Ltd.
• Contract Date: Feb 29, 2016