| 1. |
- Ancona, Antonio, 1974-, et al.
(författare)
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Monitoring and control of directed energy deposition using a laser beam
- 2023. - 1.
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Ingår i: Additive Manufacturing of High-Performance metallic Materials. - : Elsevier. - 9780323918855 - 9780323913829 ; , s. 612-638
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Bokkapitel (refereegranskat)abstract
- To be a successful competitor among other technologies, metallic laser-directed energy depositionusing a laser beam would benefit from the support of intelligent automation making the processrobust, repeatable, and cost-efficient. This calls for technology leaps towards robust and accuratedetection and estimation of the conditions during processing and control schemes for robustperformance. This chapter discusses how developments in sensor technology and model-basedsignal processing can contribute to advancements in in-process monitoring of directed energydeposition using a laser beam and how developments in model-based feedforward- and feedbackcontrol can support automation. The focus is on how machine vision, optical emission spectroscopy,thermal sensing, and electrical process signals can support monitoring, control and better processunderstanding. These approaches are industrially relevant and have a high potential to support amore sustainable manufacturing.
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| 2. |
- Elefante, Arianna, et al.
(författare)
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Detecting beam offsets in laser welding of closed-square-butt joints by wavelet analysis of an optical process signal
- 2019
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Ingår i: Optics and Laser Technology. - : Elsevier BV. - 0030-3992 .- 1879-2545. ; 109, s. 178-185
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Tidskriftsartikel (refereegranskat)abstract
- Robotized laser beam welding of closed-square-butt joints is sensitive to the positioning of the laser beam with respect to the joint since even a small offset may result in a detrimental lack of sidewall fusion. An evaluation of a system using a photodiode aligned coaxial to the processing laser beam confirms the ability to detect variations of the process conditions, such as when there is an evolution of an offset between the laser beam and the joint. Welding with different robot trajectories and with the processing laser operating in both continuous and pulsed mode provided data for this evaluation. The detection method uses wavelet analysis of the photodetector signal that carries information of the process condition revealed by the plasma plume optical emissions during welding. This experimental data have been evaluated offline. The results show the potential of this detection method that is clearly beneficial for the development of a system for welding joint tracking.
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| 3. |
- Gaudiuso, Caterina, et al.
(författare)
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Incubation during laser ablation with bursts of femtosecond pulses with picosecond delays
- 2018
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Ingår i: Optics Express. - 1094-4087. ; 26:4, s. 3801-3813
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Tidskriftsartikel (refereegranskat)abstract
- Abstract: We report on an experimental investigation of the incubation effect during irradiation of stainless steel with bursts of ultrashort laser pulses. A series of birefringent crystals was used to split the pristine 650-fs pulses into bursts of up to 32 sub-pulses with time separations of 1.5 ps and 3 ps, respectively. The number of selected bursts was varied between 50 and 1600. The threshold fluence was measured in case of Burst Mode (BM) processing depending on the burst features, i.e. the number of sub-pulses and their separation time, and on the number of bursts. We found as many values of threshold fluence as the combinations of the number of bursts and of sub-pulses constituting the bursts set to give the same total number of impinging sub-pulses. However, existing incubation models developed for Normal Pulse Mode (NPM) return, for a given number of impinging pulses, a constant value of threshold fluence. Therefore, a dependence of the incubation coefficient with the burst features was hypothesized and experimentally investigated. Numerical solutions of the Two Temperature Model (TTM) in case of irradiation with single bursts of up to 4 sub-pulses have been performed to interpret the experimental results. © 2018 Optical Society of America.
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| 4. |
- Gaudiuso, Caterina, et al.
(författare)
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Incubation effect in burst mode fs-laser ablation of stainless steel samples
- 2018
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Ingår i: Proceedings of SPIE, the International Society for Optical Engineering. - : SPIE. - 0277-786X .- 1996-756X. ; 10520
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Tidskriftsartikel (refereegranskat)abstract
- We report on an experimental study of the incubation effect during irradiation of stainless steel targets with bursts of femtosecond laser pulses at 1030 nm wavelength and 100 kHz repetition rate. The bursts were generated by splitting the pristine 650-fs laser pulses using an array of birefringent crystals which provided time separations between sub-pulses in the range from 1.5 ps to 24 ps. We measured the threshold fluence in Burst Mode, finding that it strongly depends on the bursts features. The comparison with Normal Pulse Mode revealed that the existing models introduced to explain the incubation effect during irradiation with trains of undivided pulses has to be adapted to describe incubation during Burst Mode processing. In fact, those models assume that the threshold fluence has a unique value for each number of impinging pulses in NPM, while in case of BM we observed different values of threshold fluence for fixed amount of sub-pulses but different pulse splitting. Therefore, the incubation factor coefficient depends on the burst features. It was found that incubation effect is higher in BM than NPM and that it increases with the number of sub-pulses and for shorter time delays within the burst. Two-Temperature-Model simulations in case of single pulses and bursts of up to 4 sub-pulses were performed to understand the experimental results. © Copyright SPIE.
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| 5. |
- Jadidi, Aydin, Postdoktor, et al.
(författare)
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Beam Offset Detection in Laser Stake Welding of Tee Joints Using Machine Learning and Spectrometer Measurements
- 2022
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Ingår i: Sensors. - : MDPI. - 1424-8220. ; 22:10
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Tidskriftsartikel (refereegranskat)abstract
- Laser beam welding offers high productivity and relatively low heat input and is one key enabler for efficient manufacturing of sandwich constructions. However, the process is sensitive to how the laser beam is positioned with regards to the joint, and even a small deviation of the laser beam from the correct joint position (beam offset) can cause severe defects in the produced part. With tee joints, the joint is not visible from top side, therefore traditional seam tracking methods are not applicable since they rely on visual information of the joint. Hence, there is a need for a monitoring system that can give early detection of beam offsets and stop the process to avoid defects and reduce scrap. In this paper, a monitoring system using a spectrometer is suggested and the aim is to find correlations between the spectral emissions from the process and beam offsets. The spectrometer produces high dimensional data and it is not obvious how this is related to the beam offsets. A machine learning approach is therefore suggested to find these correlations. A multi-layer perceptron neural network (MLPNN), support vector machine (SVM), learning vector quantization (LVQ), logistic regression (LR), decision tree (DT) and random forest (RF) were evaluated as classifiers. Feature selection by using random forest and non-dominated sorting genetic algorithm II (NSGAII) was applied before feeding the data to the classifiers and the obtained results of the classifiers are compared subsequently. After testing different offsets, an accuracy of 94% was achieved for real-time detection of the laser beam deviations greater than 0.9 mm from the joint center-line.
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| 6. |
- Kisielewicz, Agnieszka, et al.
(författare)
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Hot-Wire Laser-Directed Energy Deposition : Process Characteristics and Benefits of Resistive Pre-Heating of the Feedstock Wire
- 2021
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Ingår i: Metals. - : MDPI. - 2075-4701. ; 11:4, s. 1-25
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Tidskriftsartikel (refereegranskat)abstract
- This study investigates the influence of resistive pre-heating of the feedstock wire (here called hot-wire) on the stability of laser-directed energy deposition of Duplex stainless steel. Data acquired online during depositions as well as metallographic investigations revealed the process characteristic and its stability window. The online data, such as electrical signals in the pre-heating circuit and images captured from side-view of the process interaction zone gave insight on the metal transfer between the molten wire and the melt pool. The results show that the characteristics of the process, like laser-wire and wire-melt pool interaction, vary depending on the level of the wire pre-heating. In addition, application of two independent energy sources, laser beam and electrical power, allows fine-tuning of the heat input and increases penetration depth, with little influence on the height and width of the beads. This allows for better process stability as well as elimination of lack of fusion defects. Electrical signals measured in the hot-wire circuit indicate the process stability such that the resistive pre-heating can be used for in-process monitoring. The conclusion is that the resistive pre-heating gives additional means for controlling the stability and the heat input of the laser-directed energy deposition.
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| 7. |
- Kisielewicz, Agnieszka, et al.
(författare)
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In-process spectroscopic detection of chromium loss during Directed Energy Deposition of alloy 718
- 2020
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Ingår i: Materials & design. - : Elsevier BV. - 0264-1275 .- 1873-4197. ; 186
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Tidskriftsartikel (refereegranskat)abstract
- In this work, a fast optical spectrometer was used to monitor the Directed Energy Deposition (DED) process, during the deposition of Alloy 718 samples with different laser power, thus different energy inputs into the material. Spectroscopic measurements revealed the presence of excited Cr I atoms in the plasma plume. The presence was more apparent for the samples characterized by higher energy input. The Cr depletion from these samples was confirmed by lower Cr content detected by Energy-Dispersive X-ray Spectroscopy (EDS) analysis. The samples were also characterized by higher oxidation and high-temperature corrosion rates in comparison to the samples produced with low energy input. These results prove the applicability of an optical emission spectroscopic system for monitoring DED to identify process conditions leading to compositional changes and variation in the quality of the built material.
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| 8. |
- Kisielewicz, Agnieszka, et al.
(författare)
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Multi sensor monitoring of the wire-melt pool interaction inhot-wire directed energy deposition using laser beam
- 2023
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Ingår i: IOP Conference Series. - : IOP Publishing. ; , s. 1-11
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Konferensbidrag (refereegranskat)abstract
- This study investigates the combination of three sensors to improve in-process monitoring of the liquid bridge between the feedstock wire and melt pool in hot-wire Directed Energy Deposition using Laser Beam. The stability of the deposition process relies on the transfer of metal between the molten feedstock wire and melt pool. Therefore, monitoring the condition of the liquid bridge and the interaction between the feedstock wire and melt pool is crucial. By utilizing a laser-optics-integrated visible range optical spectrometer and electrical sensors measuring voltage and current, relevant process changes and indications of instabilities were detected. Combined information from the current sensor and the spectrometer provided a better understanding of the process and helped to identify deviations leading to unstable deposition modes.
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| 9. |
- Kisielewicz, Agnieszka, et al.
(författare)
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Spectroscopic monitoring of laser blown powder directed energy deposition of Alloy 718
- 2018
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Ingår i: Procedia Manufacturing. - : Elsevier BV. - 2351-9789. ; 25, s. 418-425
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Tidskriftsartikel (refereegranskat)abstract
- Experimental explorations of a spectrometer system used for in-process monitoring of the laser blown powder directed energy deposition of Alloy 718 is presented. Additive manufacturing of metals using this laser process experiences repeated heating and cooling cycles which will influence the final microstructure and chemical composition at every given point in the built. The spectrometer system disclosed, under certain process conditions, spectral lines that indicate vaporisation of chromium. Post process scanning electron microscope energy dispersive spectroscopy analysis of the deposited beads confirmed a reduction of chromium. Since the chromium concentration in Alloy 718 is correlated to corrosion resistance, this result encourages to further investigations including corrosion tests.
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| 10. |
- Mi, Yongcui, 1986-, et al.
(författare)
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Beam shaping with a deformable mirror for gap bridging in autogenous laser butt welding
- 2023
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Ingår i: Optics and Lasers in Engineering. - 0143-8166. ; 169
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Tidskriftsartikel (refereegranskat)abstract
- In autogenous laser butt welding the variability of the joint gap can cause problems in terms of weld seam quality. A suitable strategy to alleviate this is to dynamically shape the laser beam instead of a circular-shaped beam with typical Gaussian or top hat distributions. Currently available systems cannot reach sufficient performance due to both the real time control system for the shape variation and the limited laser power currently manageable. In the present work, the possibility of bridging the joint gap during welding using a deformable mirror to elongate the focused laser beam from circular to transversal elliptical shape was investigated. The effect of the beam shaping on the geometry of the weld pool and of the weld cross sections was analysed, for different values of the gap in comparison with a circular Gaussian beam. It was demonstrated that the adoption of a transversal elliptical laser beam makes the welding process more stable, especially for large gaps (i.e. larger than the circular beam radius). Thanks to the beam shaping, the extension of the fused zone (in terms of the cross section area, height and width) resulted to be less sensitive to the gap's dimension; in addition, the extension of the heat affected zone and the presence of undercuts were evidently reduced.
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