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Review
. 2021 Mar 19;14(6):1511.
doi: 10.3390/ma14061511.

In Situ Monitoring of Additive Manufacturing Using Digital Image Correlation: A Review

Filipa G Cunha  1 , Telmo G Santos  1 , José Xavier  1
Affiliations
Review

In Situ Monitoring of Additive Manufacturing Using Digital Image Correlation: A Review

Filipa G Cunha et al. Materials (Basel). .

Abstract

This paper is a critical review of in situ full-field measurements provided by digital image correlation (DIC) for inspecting and enhancing additive manufacturing (AM) processes. The principle of DIC is firstly recalled and its applicability during different AM processes systematically addressed. Relevant customisations of DIC in AM processes are highlighted regarding optical system, lighting and speckled pattern procedures. A perspective is given in view of the impact of in situ monitoring regarding AM processes based on target subjects concerning defect characterisation, evaluation of residual stresses, geometric distortions, strain measurements, numerical modelling validation and material characterisation. Finally, a case study on in situ measurements with DIC for wire and arc additive manufacturing (WAAM) is presented emphasizing opportunities, challenges and solutions.

Keywords: additive manufacturing; digital image correlation; in situ; monitoring.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
Number of publications in Scopus for different full-field optical techniques coupled with the searching keyword in situ measurements (units: %).
Figure 2
Figure 2
Number of publications for the different optical techniques with in situ measurements.
Figure 3
Figure 3
Applications of in situ measurements using DIC.
Figure 4
Figure 4
WAAM and DIC set-ups.
Figure 5
Figure 5
Acquired original image of the WAAM process for DIC purposes.
Figure 6
Figure 6
Strain in the horizontal direction calculated from the original image of Figure 4.
Figure 7
Figure 7
Acquired original image of the WAAM process for DIC purposes. In this case, a metallic bulkhead was used for radiation shield and to reduce the projections.
Figure 8
Figure 8
Principal strain calculated from the original image of Figure 6.
See this image and copyright information in PMC

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