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Online Quality Control of Powder Bed Fusion with High-Resolution Eddy Current Testing Inductive Sensor Arrays.

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Summary

A new eddy current array (ECA) system enables real-time, layer-by-layer quality control for powder bed fusion (PBF) additive manufacturing. This innovation improves PBF part design, process optimization, and defect detection.

Keywords:
additive manufacturingeddy current testinginductive sensor arrayspowder bed fusion

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Non-Destructive Testing

Background:

  • Powder Bed Fusion (PBF) is a key additive manufacturing technology.
  • Real-time quality control is crucial for PBF process optimization and defect detection.
  • Existing methods for in-situ monitoring of PBF parts have limitations.

Purpose of the Study:

  • To develop and validate a novel eddy current array (ECA) system for real-time, layer-by-layer quality control in PBF.
  • To integrate the ECA system into the recoater of a PBF machine for spatially resolved electrical conductivity imaging.
  • To demonstrate the system's capability in detecting metallic structures and assessing PBF part quality.

Main Methods:

  • Development of a 40-sensor ECA system with 1 mm pitch, capable of full array readout every 0.192 mm at 100 mm/s recoater speed.
  • Implementation of advanced mixed-signal processing techniques and careful electromagnetic configuration for array scalability.
  • Experimental validation using stainless steel 316L parts in both laboratory and real-time PBF environments.

Main Results:

  • Successful integration of the ECA system into the PBF recoater for in-situ monitoring.
  • Detection of metallic structures and confirmation of system performance in real-time PBF conditions.
  • Achieved a signal-to-noise ratio (SNR) of 26.5 dB, effectively discriminating metal from air.

Conclusions:

  • The developed ECA system offers a viable solution for real-time, layer-by-layer quality control in PBF additive manufacturing.
  • The system's ability to provide spatially resolved electrical conductivity imaging has significant potential for process optimization and defect detection.
  • Further development could enhance PBF part design and overall manufacturing reliability.