Acoustic emission monitoring of a laser powder bed fusion process

Additive manufacturing (AM) metal parts offers opportunities for various industrial applications. From individual production of spare parts for unique mechanical components to prototyping of complex structures, the possibilities of production using the additive manufacturing process are manifold. One common AM technique is the Laser Powder Bed Fusion (PBF-LB/M) process, where a laser is used to selectively melt metal powder and create the parts layer wise as designed in a model. During manufacturing certain defects like pores, cracks and lack of fusion may be created in the built parts. As AM parts often have complex geometries, a postprocess non-destructive testing is difficult or even not possible. Thus, different optical monitoring techniques are applied to detect flaws during the build process with the aim to detect and repair defects right away during the manufacturing process. However, optical monitoring system require a clear view of the melt pool and quite expensive equipment. Acoustic monitoring by AE sensors attached to the built plate would be a cheaper alternative which also can be used without visual contact to the building chamber. This paper shows a first approach of an AE based process monitoring. The build plate of a PBF-LB/M machine therefore was adapted to hold four AE sensors that are then used to monitor the process. The build process itself creates AE signals caused by the melting and cooling and the mechanical application of powder. The formation of pores and cracks is expected to create additional acoustic emissions that will be distinct from the AE pattern from the printing process. This AE signals can be linked to the different layers of the printed part or in the long run to the laser position. Results from the first tests in a customized LPBF machine will be shown as well as the implementation of AE into the PBF-LB/M machine.