In-situ monitoring of powder bed fusion of metals using eddy current testing

Powder bed fusion of metals (PBF-LB/M) is the most commonly used additive manufacturing process for layerwise production metal parts. Although technology has developed rapidly in recent years, manufactured parts still lack consistent quality primarily owing to process-inherent variability, and effective sensing technologies enabling ability control during part production. Thus, there are high costs caused by rigorous post-process inspection steps required provide compliant certificates. In contrast typically deployed in-situ technologies, eddy current testing (ECT) a standardized nondestructive (NDT) technique able certificates according existing standards. This study investigates potential ECT as an monitoring PBF-LB/M. Parts made from AlSi10Mg were on PBF-LB/M machine using different parameters yielding relative densities ranging 99%– 99.7%. During build cycle, measured layer-by-layer with system mounted recoater. Signal analysis methods which effectively separate calibrate electrical conductivity component (relative conductivity) distance (lift-off) signals. The was then compared X-ray micro-computed tomography (μCT) measurement data demonstrating that layer-to-layer differences density about 0.1% can be successfully detected via ECT. addition, lift-off monitor thickness consolidated layers height. results show paving way deploying NDT PBF-LB/M-manufactured