Combining thermal imaging and spectral pyrometry for express temperature mapping in additive manufacturing.

A compact and low-cost two-dimensional (2D) thermal imager was developed for real-time temperature mapping of a melt pool during coaxial laser cladding (the additive manufacturing technique). The device combines a color CMOS camera and a compact spectrometer. The spectrometer was utilized for internal calibration and validation of a 2D temperature map that was acquired by the CMOS camera. The remarkable feature of the thermal imager is that camera images are calibrated directly during the measurement process utilizing spectral pyrometry. Additionally, the spectrometer decreased a potential systematic error due to a spectrum contribution from atomic/ionic lines emission. The spectral pyrometry provided temperature accuracy measurements of ±23K while two-dimensional (2D) temperature mapping by two-color pyrometry accuracy was estimated as ±38K in the range of 1700-3500 K. The system has been installed at a coaxial laser cladding head for real-time temperature mapping. The system was developed for measuring a melt pool during laser cladding production of a high wear-resistant coating (tungsten carbide particles in a nickel matrix). Tungsten carbides powder flow rate has been changed sequentially from 5 to 27 g/min by powder feeder programming, which resulted in a variation of melt pool dimensions and temperature maps during the cladding process.

In situ laser-induced breakdown spectroscopy measurements during laser welding of superalloy.

Laser-induced breakdown spectroscopy (LIBS) has been utilized for in situ diagnostics of the laser welding process. The influence of different weld spot areas (melt pool, solid weld) on LIBS signals and plasma properties has been studied in detail. Liquid metal sampling and high target surface temperature of the melt enhance LIBS plasma intensity and increase plasma temperature. The influence of laser welding process parameters on LIBS measurements has been studied in order to differentiate optimal and defective laser welding. In case of defective laser welding, the melt pool was intensively boiling, so we have observed greater LIBS signals but poor reproducibility. For the first time, the LIBS technique was demonstrated to detect defective laser welding during in situ measurements utilizing atomic and ionic line comparison by paired sample t-test hypotheses testing.

Laser-induced breakdown spectroscopy for three-dimensional elemental mapping of composite materials synthesized by additive technologies.

Three-dimensional multi-elemental mapping of composite wear-resistant coatings by laser-induced breakdown spectroscopy has been demonstrated for the first time, to the best of our knowledge. Individual clads of 1560 nickel alloy reinforced with tungsten carbide were synthesized by a co-axial laser cladding technique. Electron energy dispersive x-ray spectroscopy revealed elemental maps for major elements (W, Ni, Co, Cr, Fe) but failed to measure silicon and carbon. Laser-induced breakdown spectroscopy was utilized for elemental mapping of carbon and all other elements of interest. It was demonstrated that three-dimensional elemental profiling for a few tens of micrometers requires substantial laser spot overlapping during the scanning procedure in order to achieve good accuracy of depth measurements. Elemental maps for nickel, iron, chromium, silicon, tungsten, and carbon were quantified for 900 µm×900 µm×45 µm volume with 30 µm lateral and 4 µm depth resolution in the case of tungsten carbide particles in nickel alloy.