SIM-AM 2025

Keynote

Shining Light on Hidden Defects: In-Situ Active Thermography in Metal AM

  • Sauer, Christian (THWS)
  • Höfflin, Dennis (THWS)
  • Schiffler, Andreas (THWS)
  • Hartmann, Jürgen (THWS)

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Laser Powder Bed Fusion of Metals (PBF-LB/M) enables the fabrication of highly complex metallic components, yet its reliability is often compromised by process-induced defects. Consequently, robust in-situ process monitoring is indispensable for ensuring part quality and enabling future closed-loop control strategies [1]. This contribution presents a significant advancement in real-time PBF-LB/M mon- itoring through Synchronized Path Infrared Thermography (SPIT), facilitated by a unique dual scan head system designed specifically for precise, absolute temperature measurements [2]. Standard on-axis methods often face restricted wavelength observation and struggle with sensitivity at lower temperature ranges, hindering comprehensive thermal analysis. Conversely, typical off-axis systems frequently involve compromises between spatial resolution, the extent of the monitored area, and achievable frame rates. The core innovation is the dual scan head architecture: one galvanometer scanner directs the processing laser beam, while a second, fully independent scanner dynamically steers the narrow field-of-view of a high-speed infrared camera. This second scanner executes the SPIT strategy, ensuring the camera’s measurement spot tracks the laser’s path at a defined, optimized offset distance, capturing the thermal signature from the heat-affected zone after the laser has passed. For validation, stainless steel samples containing intentionally embedded subsurface defects were manufactured and subsequently processed under varying laser parameters. This method uniquely synergizes the high spatial resolution potential often associated with coaxial viewing and the positional and spectral flexibility of off-axis systems. By enabling precise measurements during the active build process and demonstrating its capability for identifying defect indicators, this technique provides valuable data for validating thermal simulations, enhancing process understanding, and ultimately paving the way for advanced quality assurance and real-time adaptive control in PBF-LB/M.