In-situ inspection system for additive manufacturing based on phase measurement profilometry

Yue Liu, Zonghua Zhang, Liam Blunt, Grant Saunby, Jason Dawes, Ben Blackham, Hussein Abdul Rahman, Chris Smith, Feng Gao, Xiangqian Jiang

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

Additi ve manufa cturing (AM) of me tal powde r by ele ctron bea m fusion offe rs sig nifi cant adva ntages compa re d with tradi tional subtra cti ve manufa cturing te chniques . AM has de veloped signi fi cantl y ove r re cent years and is now widel y used in acade mi c a nd industry, pa rti cula rl y in ae rospa ce and medi cal de vi ce manufa cture. AM te chniques s till ha ve many unsol ved challenges, such as the de te ction of pa rt defe cts de velope d duri ng the AM building process. Powde r deli ve ry is a process tha t occurs many thousands of times during the build cycle, consequentl y the assessment of deli ve ry quality would be important for in-build quality control . This pape r des cribes the de velopment of an inspe ction s ys tem for the powde r bed deli ve ry by using phase measure ment profilome try. A compensa tion algori thm for nonlinear e ffe ct is inves tiga ted in orde r to i mpro ve the accura cy and tra ceability of the inspe cti on te chnique. A te mporal s ynchronisation te chnique is employe d to re duce the da ta capture ti me down to 2 se conds for ea ch inspe ction. Addi tionall y a novel calibra tion me thod based on a surfa ce fitting algori thm is inves tiga ted and employed to reduce the influence of phase e rror and random noise. The resul ts show the deploye d calibra tion protocol can effe cti vel y enhance the inspe ction a ccura cy and sol ve hi ghe r ha rmoni c proble ms. The proposed in -situ inspe ction te chnique was deploye d on a prototype ele ctron beam melting (EBM) AM machine. An e xample of e xcessi ve powde r deli ve ry due to rake damage during a real pa rt build i s used to de mons tra te the s ys te m capability on the a ctual EBea m ma chine. Addi tionall y, two e xa mples of e xcessive powde r deli ve ry a cross a reas of the powde r bed and the resul ting scanning results obtained duri ng the building are shown. Expe rime ntal resul ts de monstra te tha t powde r defe cts can be e ffi cientl y inspe cted wi th the proposed te chnique and inspe ction a ccura cy is improved s i gnificantly by a pplying the proposed calibration me thod and compensation algorithm.

LanguageEnglish
Title of host publicationEuropean Society for Precision Engineering and Nanotechnology, Conference Proceedings - 19th International Conference and Exhibition, EUSPEN 2019
EditorsC. Nisbet, Richard K. Leach, D. Billington, D. Phillips
Publishereuspen
Pages324-327
Number of pages4
ISBN (Electronic)9780995775145
Publication statusPublished - 2019
Event19th International Conference of the European Society for Precision Engineering and Nanotechnology - Euskalduna, Bilbao, Spain
Duration: 3 Jun 20197 Jun 2019
Conference number: 19
https://www.euspen.eu/events/19th-ice-bilbao/

Conference

Conference19th International Conference of the European Society for Precision Engineering and Nanotechnology
Abbreviated titleEUSPEN 2019
CountrySpain
CityBilbao
Period3/06/197/06/19
Internet address

Fingerprint

3D printers
Profilometry
Phase measurement
Sols
Quality control
inspection
Melting
Fusion reactions
Tolnaftate
manufacturing
Inspection
Calibration
Scanning
Polymethyl Methacrylate
Industry
beds
rakes
random noise
quality control
fusion

Cite this

Liu, Y., Zhang, Z., Blunt, L., Saunby, G., Dawes, J., Blackham, B., ... Jiang, X. (2019). In-situ inspection system for additive manufacturing based on phase measurement profilometry. In C. Nisbet, R. K. Leach, D. Billington, & D. Phillips (Eds.), European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 19th International Conference and Exhibition, EUSPEN 2019 (pp. 324-327). euspen.
Liu, Yue ; Zhang, Zonghua ; Blunt, Liam ; Saunby, Grant ; Dawes, Jason ; Blackham, Ben ; Rahman, Hussein Abdul ; Smith, Chris ; Gao, Feng ; Jiang, Xiangqian. / In-situ inspection system for additive manufacturing based on phase measurement profilometry. European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 19th International Conference and Exhibition, EUSPEN 2019. editor / C. Nisbet ; Richard K. Leach ; D. Billington ; D. Phillips. euspen, 2019. pp. 324-327
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abstract = "Additi ve manufa cturing (AM) of me tal powde r by ele ctron bea m fusion offe rs sig nifi cant adva ntages compa re d with tradi tional subtra cti ve manufa cturing te chniques . AM has de veloped signi fi cantl y ove r re cent years and is now widel y used in acade mi c a nd industry, pa rti cula rl y in ae rospa ce and medi cal de vi ce manufa cture. AM te chniques s till ha ve many unsol ved challenges, such as the de te ction of pa rt defe cts de velope d duri ng the AM building process. Powde r deli ve ry is a process tha t occurs many thousands of times during the build cycle, consequentl y the assessment of deli ve ry quality would be important for in-build quality control . This pape r des cribes the de velopment of an inspe ction s ys tem for the powde r bed deli ve ry by using phase measure ment profilome try. A compensa tion algori thm for nonlinear e ffe ct is inves tiga ted in orde r to i mpro ve the accura cy and tra ceability of the inspe cti on te chnique. A te mporal s ynchronisation te chnique is employe d to re duce the da ta capture ti me down to 2 se conds for ea ch inspe ction. Addi tionall y a novel calibra tion me thod based on a surfa ce fitting algori thm is inves tiga ted and employed to reduce the influence of phase e rror and random noise. The resul ts show the deploye d calibra tion protocol can effe cti vel y enhance the inspe ction a ccura cy and sol ve hi ghe r ha rmoni c proble ms. The proposed in -situ inspe ction te chnique was deploye d on a prototype ele ctron beam melting (EBM) AM machine. An e xample of e xcessi ve powde r deli ve ry due to rake damage during a real pa rt build i s used to de mons tra te the s ys te m capability on the a ctual EBea m ma chine. Addi tionall y, two e xa mples of e xcessive powde r deli ve ry a cross a reas of the powde r bed and the resul ting scanning results obtained duri ng the building are shown. Expe rime ntal resul ts de monstra te tha t powde r defe cts can be e ffi cientl y inspe cted wi th the proposed te chnique and inspe ction a ccura cy is improved s i gnificantly by a pplying the proposed calibration me thod and compensation algorithm.",
keywords = "Additive manufacturing, Electron beam bed fusion, Fringe projection technique, In-situ measurement, Surface geometry, System calibration",
author = "Yue Liu and Zonghua Zhang and Liam Blunt and Grant Saunby and Jason Dawes and Ben Blackham and Rahman, {Hussein Abdul} and Chris Smith and Feng Gao and Xiangqian Jiang",
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language = "English",
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editor = "C. Nisbet and Leach, {Richard K.} and D. Billington and D. Phillips",
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Liu, Y, Zhang, Z, Blunt, L, Saunby, G, Dawes, J, Blackham, B, Rahman, HA, Smith, C, Gao, F & Jiang, X 2019, In-situ inspection system for additive manufacturing based on phase measurement profilometry. in C Nisbet, RK Leach, D Billington & D Phillips (eds), European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 19th International Conference and Exhibition, EUSPEN 2019. euspen, pp. 324-327, 19th International Conference of the European Society for Precision Engineering and Nanotechnology, Bilbao, Spain, 3/06/19.

In-situ inspection system for additive manufacturing based on phase measurement profilometry. / Liu, Yue; Zhang, Zonghua; Blunt, Liam; Saunby, Grant; Dawes, Jason; Blackham, Ben; Rahman, Hussein Abdul; Smith, Chris; Gao, Feng; Jiang, Xiangqian.

European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 19th International Conference and Exhibition, EUSPEN 2019. ed. / C. Nisbet; Richard K. Leach; D. Billington; D. Phillips. euspen, 2019. p. 324-327.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

TY - GEN

T1 - In-situ inspection system for additive manufacturing based on phase measurement profilometry

AU - Liu, Yue

AU - Zhang, Zonghua

AU - Blunt, Liam

AU - Saunby, Grant

AU - Dawes, Jason

AU - Blackham, Ben

AU - Rahman, Hussein Abdul

AU - Smith, Chris

AU - Gao, Feng

AU - Jiang, Xiangqian

PY - 2019

Y1 - 2019

N2 - Additi ve manufa cturing (AM) of me tal powde r by ele ctron bea m fusion offe rs sig nifi cant adva ntages compa re d with tradi tional subtra cti ve manufa cturing te chniques . AM has de veloped signi fi cantl y ove r re cent years and is now widel y used in acade mi c a nd industry, pa rti cula rl y in ae rospa ce and medi cal de vi ce manufa cture. AM te chniques s till ha ve many unsol ved challenges, such as the de te ction of pa rt defe cts de velope d duri ng the AM building process. Powde r deli ve ry is a process tha t occurs many thousands of times during the build cycle, consequentl y the assessment of deli ve ry quality would be important for in-build quality control . This pape r des cribes the de velopment of an inspe ction s ys tem for the powde r bed deli ve ry by using phase measure ment profilome try. A compensa tion algori thm for nonlinear e ffe ct is inves tiga ted in orde r to i mpro ve the accura cy and tra ceability of the inspe cti on te chnique. A te mporal s ynchronisation te chnique is employe d to re duce the da ta capture ti me down to 2 se conds for ea ch inspe ction. Addi tionall y a novel calibra tion me thod based on a surfa ce fitting algori thm is inves tiga ted and employed to reduce the influence of phase e rror and random noise. The resul ts show the deploye d calibra tion protocol can effe cti vel y enhance the inspe ction a ccura cy and sol ve hi ghe r ha rmoni c proble ms. The proposed in -situ inspe ction te chnique was deploye d on a prototype ele ctron beam melting (EBM) AM machine. An e xample of e xcessi ve powde r deli ve ry due to rake damage during a real pa rt build i s used to de mons tra te the s ys te m capability on the a ctual EBea m ma chine. Addi tionall y, two e xa mples of e xcessive powde r deli ve ry a cross a reas of the powde r bed and the resul ting scanning results obtained duri ng the building are shown. Expe rime ntal resul ts de monstra te tha t powde r defe cts can be e ffi cientl y inspe cted wi th the proposed te chnique and inspe ction a ccura cy is improved s i gnificantly by a pplying the proposed calibration me thod and compensation algorithm.

AB - Additi ve manufa cturing (AM) of me tal powde r by ele ctron bea m fusion offe rs sig nifi cant adva ntages compa re d with tradi tional subtra cti ve manufa cturing te chniques . AM has de veloped signi fi cantl y ove r re cent years and is now widel y used in acade mi c a nd industry, pa rti cula rl y in ae rospa ce and medi cal de vi ce manufa cture. AM te chniques s till ha ve many unsol ved challenges, such as the de te ction of pa rt defe cts de velope d duri ng the AM building process. Powde r deli ve ry is a process tha t occurs many thousands of times during the build cycle, consequentl y the assessment of deli ve ry quality would be important for in-build quality control . This pape r des cribes the de velopment of an inspe ction s ys tem for the powde r bed deli ve ry by using phase measure ment profilome try. A compensa tion algori thm for nonlinear e ffe ct is inves tiga ted in orde r to i mpro ve the accura cy and tra ceability of the inspe cti on te chnique. A te mporal s ynchronisation te chnique is employe d to re duce the da ta capture ti me down to 2 se conds for ea ch inspe ction. Addi tionall y a novel calibra tion me thod based on a surfa ce fitting algori thm is inves tiga ted and employed to reduce the influence of phase e rror and random noise. The resul ts show the deploye d calibra tion protocol can effe cti vel y enhance the inspe ction a ccura cy and sol ve hi ghe r ha rmoni c proble ms. The proposed in -situ inspe ction te chnique was deploye d on a prototype ele ctron beam melting (EBM) AM machine. An e xample of e xcessi ve powde r deli ve ry due to rake damage during a real pa rt build i s used to de mons tra te the s ys te m capability on the a ctual EBea m ma chine. Addi tionall y, two e xa mples of e xcessive powde r deli ve ry a cross a reas of the powde r bed and the resul ting scanning results obtained duri ng the building are shown. Expe rime ntal resul ts de monstra te tha t powde r defe cts can be e ffi cientl y inspe cted wi th the proposed te chnique and inspe ction a ccura cy is improved s i gnificantly by a pplying the proposed calibration me thod and compensation algorithm.

KW - Additive manufacturing

KW - Electron beam bed fusion

KW - Fringe projection technique

KW - In-situ measurement

KW - Surface geometry

KW - System calibration

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BT - European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 19th International Conference and Exhibition, EUSPEN 2019

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Liu Y, Zhang Z, Blunt L, Saunby G, Dawes J, Blackham B et al. In-situ inspection system for additive manufacturing based on phase measurement profilometry. In Nisbet C, Leach RK, Billington D, Phillips D, editors, European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 19th International Conference and Exhibition, EUSPEN 2019. euspen. 2019. p. 324-327