Zero defect manufacturing in laser metal deposition

Project aim:

The objective is to develop a Data Acquisition Platform capable of in-situ data collection and processing using multiple sensors. An offline study of this data is to be made in correlation to machine parameters and defects so that certain trends and anomalies may be recognized. Once these patterns and trends are understood, a control algorithm is to be developed.

Project background:

Laser Metal Deposition is a metal 3D printing process where powder metal is jetted into the laser beam at the point of deposition with the help of a carrier gas. The laser melts the powder material onto the substrate creating a Meltpool. The Meltpool solidifies upon cooling after the laser moves off the deposition area. This layer-by-layer deposition of material can create a complete 3D component with the help of 3D CAD software and a CNC machine. The process is not readily adapted for operations in the aerospace and automotive industry due to the defects created in the work piece during the LMD process. Broadly, there are two types of defects in Laser Metal Deposition; pores and cracks. Currently due to hardware and methodology limitations of detection, a completely defect-free product is very difficult to produce.