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In-Situ Monitoring of Interplay Between Melt Pool, Spatter and Vapor in Laser Powder Bed Fusion Additive Manufacturing

Xin Lin^1,2,3, Kunpeng Zhu^1,2,3,*

1 Precision Manufacturing Institute, Wuhan University of Science and Technology, Heping Road, Qingshan district, Wuhan, 430081, China
2 Hubei Key Laboratory of Theory and Application of Advanced Materials Mechanics, Wuhan University of Technology, Heping Road, Qingshan district, Wuhan, 430081, China
3 Institute of Intelligent Machines, Hefei Institutes of Physical Science, Chinese Academy of Sciences, Huihong Building, Changzhou, 213164, China

* Corresponding Author: Kunpeng Zhu. Email:

The International Conference on Computational & Experimental Engineering and Sciences 2024, 30(2), 1-1. https://doi.org/10.32604/icces.2024.012499

Abstract

This paper reveals the interplay mechanism between melt pool, spattering and vapors, aiming to further improve the forming quality through in-situ monitoring with a CMOS camera. A Residual Network based on Convolutional Block Attention Module and Focal loss function is proposed to extract multi-scale features of single tracks and learn about their behavior changes. A t-SNE clustering analysis is utilized to analysis a large amount of time sequence data on the melt pool by collecting the schlieren photographs. It is found that patterns of unstable melt pool changing corelate to the defects in single tracks, such as, regularity, necking, surface humping, flat-wide and discontinuity. According to signal processing and statistical analysis, the laser powder influences the spatter' angle more than scanning speed in the mode where vapor entertainment acts as the driving force inducing solid spatter ejection. Vapor plume inclines against the scanning direction but alters direction until the line energy exceeds the threshold of 1.5 J/mm.

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Keywords

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