Detecting Selective Laser Melting Beam Power from Ultrasonic Temporal and Spectral Responses of Phononic Crystal Artifacts Toward In-Situ Real-Time Quality Monitoring
- PMID: 39734735
- PMCID: PMC11669835
- DOI: 10.1089/3dp.2023.0063
Detecting Selective Laser Melting Beam Power from Ultrasonic Temporal and Spectral Responses of Phononic Crystal Artifacts Toward In-Situ Real-Time Quality Monitoring
Abstract
Unlike many conventional manufacturing techniques, 3D Printing/Additive Manufacturing (3DP/AM) fabrication creates builds with unprecedented degrees of structural and geometrical complexities. However, uncertainties in 3DP/AM processes and material attributes could cause geometric and structural quality issues in resulting builds and products. Evaluating the sensitivity of process parameters and material properties for process optimization, quality assessment, and closed-loop control is crucial in practice. This study presents a framework for a nondestructive in situ real-time ultrasonic monitoring approach based on the temporal and spectral dispersion analyses of specially designed artifacts with periodic internal structures called Phononic Crystal Artifacts (PCAs). The framework's effectiveness for in-situ monitoring of laser beam power in a Selective Laser Melting (SLM) process is experimentally demonstrated. A PCA is significantly simpler and/or smaller than the actual build, but it represents a specific subset of its geometric and mechanical features and complexities, which are relevant to the objectives of a quality monitoring program. Specifically, the influence of the SLM printer laser beam power on the ultrasonic responses and dispersion properties of stainless steel 316L PCAs is evaluated. Two sensing strategies based on cross-correlation and spectral dispersion analysis of ultrasonic waves transmitted in the artifacts are presented and utilized for evaluating the effect of laser power level on the mechanical and microgeometric properties of fabricated PCAs. The reported novel framework's potential in critical quality monitoring applications for in-situ real-time quality assessment of 3DP/AM processes is also discussed.
Keywords: in situ real-time quality assessment; phononic crystal artifacts; real-time laser power monitoring; selective laser melting (SLM); spectral methods; stainless steel 316L (SS316L); ultrasonic elastic waves.
Copyright 2023, Mary Ann Liebert, Inc., publishers.
Similar articles
-
Ultrasonic Evaluation of Laser Scanning Speed Effect on the Spectral Properties of Three-Dimensional-Printed Metal Phononic Crystal Artifacts.3D Print Addit Manuf. 2024 Jun 18;11(3):e1087-e1099. doi: 10.1089/3dp.2022.0259. eCollection 2024 Jun. 3D Print Addit Manuf. 2024. PMID: 39359574 Free PMC article.
-
A Review of Optimization of Additively Manufactured 316/316L Stainless Steel Process Parameters, Post-Processing Strategies, and Defect Mitigation.Materials (Basel). 2025 Jun 17;18(12):2870. doi: 10.3390/ma18122870. Materials (Basel). 2025. PMID: 40573001 Free PMC article. Review.
-
A rapid and systematic review of the clinical effectiveness and cost-effectiveness of topotecan for ovarian cancer.Health Technol Assess. 2001;5(28):1-110. doi: 10.3310/hta5280. Health Technol Assess. 2001. PMID: 11701100
-
Medical and surgical interventions for the treatment of usual-type vulval intraepithelial neoplasia.Cochrane Database Syst Rev. 2016 Jan 5;2016(1):CD011837. doi: 10.1002/14651858.CD011837.pub2. Cochrane Database Syst Rev. 2016. PMID: 26728940 Free PMC article.
-
Home treatment for mental health problems: a systematic review.Health Technol Assess. 2001;5(15):1-139. doi: 10.3310/hta5150. Health Technol Assess. 2001. PMID: 11532236
References
-
- Ngo TD, Kashani A, Imbalzano G, et al. . Additive manufacturing (3D printing): A review of materials, methods, applications and challenges. Compos Part B Eng 2018;143:172–196; doi: 10.1016/j.compositesb.2018.02.012 - DOI
-
- Mani M, Lane BM, Donmez MA, et al. . Measurement Science Needs for Real-time Control of Additive Manufacturing Powder Bed Fusion Processes. Report Number 8036. National Institute Standards and Technology: Gaithersburg, MD; 2015.
-
- Sacco E, Moon SK. Additive manufacturing for space: Status and promises. Int J Adv Manuf Technol 2019;105(10):4123–4146; doi: 10.1007/s00170-019-03786-z - DOI
-
- Yap CY, Chua CK, Dong ZL, et al. . Review of selective laser melting: Materials and applications. Appl Phys Rev 2015;2(4):041101; doi: 10.1063/1.4935926 - DOI
-
- Chen J, Wang X, Pan Y. Influence of laser power and scan speed on the microstructure and properties of GH4169 alloy prepared by selective laser melting. IOP Conf Ser Mater Sci Eng 2019;688(3):033064; doi: 10.1088/1757-899X/688/3/033064 - DOI