Visual sensing and image processing for error detection in laser metal wire deposition

A. I. Adediran; A. Nycz; A. Thornton; L. J. Love

Visual sensing and image processing for error detection in laser metal wire deposition

A. I. Adediran, A. Nycz, A. Thornton, L. J. Love

Manufacturing Robotics and Control

Research output: Contribution to conference › Paper › peer-review

Abstract

Laser metal deposition with wire (LMD-w) involves feeding metal wire through a nozzle and melting the wire with a high-power laser. With efficient process control, i.e. sensing, processing, and feedback correction of errors, the technology has the potential to change the course of manufacturing. However, the limitation most often encountered in LMD is the difficulty in controlling the process. Monitoring and control of metal additive manufacturing processes has been mostly researched on powder-based systems and has not been extensively investigated on metal wire feed systems. This work proposes a method for detecting discontinuities in a deposited layer in the LMD-w process via optical inspection and processing of images obtained from a high-resolution camera. The aim is to develop an effective sensing module that automatically detects irregularities in each layer before proceeding to subsequent layers, which will reduce part porosity and improve inter-layer bond integrity.

Original language	English
Pages	2034-2044
Number of pages	11
State	Published - 2020
Event	28th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2017 - Austin, United States Duration: Aug 7 2017 → Aug 9 2017

Conference

Conference	28th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2017
Country/Territory	United States
City	Austin
Period	08/7/17 → 08/9/17

Funding

This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/ doe-public-access-plan).

Funders	Funder number
Bredesen Center for Interdisciplinary Research and Graduate Education, University of Tennessee
GKN Aerospace
Oak Ridge National Laboratory

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Cite this

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title = "Visual sensing and image processing for error detection in laser metal wire deposition",

abstract = "Laser metal deposition with wire (LMD-w) involves feeding metal wire through a nozzle and melting the wire with a high-power laser. With efficient process control, i.e. sensing, processing, and feedback correction of errors, the technology has the potential to change the course of manufacturing. However, the limitation most often encountered in LMD is the difficulty in controlling the process. Monitoring and control of metal additive manufacturing processes has been mostly researched on powder-based systems and has not been extensively investigated on metal wire feed systems. This work proposes a method for detecting discontinuities in a deposited layer in the LMD-w process via optical inspection and processing of images obtained from a high-resolution camera. The aim is to develop an effective sensing module that automatically detects irregularities in each layer before proceeding to subsequent layers, which will reduce part porosity and improve inter-layer bond integrity.",

author = "Adediran, {A. I.} and A. Nycz and A. Thornton and Love, {L. J.}",

note = "Publisher Copyright: Copyright {\textcopyright} SFF 2017.All rights reserved.; 28th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2017 ; Conference date: 07-08-2017 Through 09-08-2017",

year = "2020",

language = "English",

pages = "2034--2044",

}

Visual sensing and image processing for error detection in laser metal wire deposition. / Adediran, A. I.; Nycz, A.; Thornton, A. et al.
2020. 2034-2044 Paper presented at 28th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2017, Austin, United States.

Research output: Contribution to conference › Paper › peer-review

TY - CONF

T1 - Visual sensing and image processing for error detection in laser metal wire deposition

AU - Adediran, A. I.

AU - Nycz, A.

AU - Thornton, A.

AU - Love, L. J.

PY - 2020

Y1 - 2020

N2 - Laser metal deposition with wire (LMD-w) involves feeding metal wire through a nozzle and melting the wire with a high-power laser. With efficient process control, i.e. sensing, processing, and feedback correction of errors, the technology has the potential to change the course of manufacturing. However, the limitation most often encountered in LMD is the difficulty in controlling the process. Monitoring and control of metal additive manufacturing processes has been mostly researched on powder-based systems and has not been extensively investigated on metal wire feed systems. This work proposes a method for detecting discontinuities in a deposited layer in the LMD-w process via optical inspection and processing of images obtained from a high-resolution camera. The aim is to develop an effective sensing module that automatically detects irregularities in each layer before proceeding to subsequent layers, which will reduce part porosity and improve inter-layer bond integrity.

AB - Laser metal deposition with wire (LMD-w) involves feeding metal wire through a nozzle and melting the wire with a high-power laser. With efficient process control, i.e. sensing, processing, and feedback correction of errors, the technology has the potential to change the course of manufacturing. However, the limitation most often encountered in LMD is the difficulty in controlling the process. Monitoring and control of metal additive manufacturing processes has been mostly researched on powder-based systems and has not been extensively investigated on metal wire feed systems. This work proposes a method for detecting discontinuities in a deposited layer in the LMD-w process via optical inspection and processing of images obtained from a high-resolution camera. The aim is to develop an effective sensing module that automatically detects irregularities in each layer before proceeding to subsequent layers, which will reduce part porosity and improve inter-layer bond integrity.

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M3 - Paper

AN - SCOPUS:85085043143

SP - 2034

EP - 2044

T2 - 28th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2017

Y2 - 7 August 2017 through 9 August 2017

ER -

Visual sensing and image processing for error detection in laser metal wire deposition

Abstract

Conference

Funding

UN SDGs

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