Abstract
Laser-foil-printing (LFP) is an additive manufacturing (AM) technique offering advantages over traditional powder-based methods. A deeper understanding of the melt pool dynamics is crucial for optimizing process parameters and achieving high-quality builds. This paper presents a combined approach utilizing numerical simulations and in-situ thermographic monitoring to investigate the relationship between scanning strategies, melt pool dimensions, and cooling rate in LFP. The numerical simulations are employed to predict melt pool behavior using a time-dependent thermal finite element analysis (FEA). Results demonstrate that the simulations accurately predict melt pool dimensions, showing strong agreement with experimental data. Simultaneously, real-time melt pool dynamics were monitored through in-situ thermographic techniques, with calibration performed using an empirically known melt pool width for emissivity determination. The continuous line scanning strategy resulted in a gradual increase in cooling rates along the scanning path, while the discrete spot scanning strategy maintained stable cooling rates at each weld spot.
Recommended Citation
T. Turk et al., "In-situ Thermographic Monitoring and Numerical Simulations of Laser-foil-printing Additive Manufacturing," Virtual and Physical Prototyping, vol. 20, no. 1, article no. e2440609, Taylor and Francis Group; Taylor and Francis, Jan 2025.
The definitive version is available at https://doi.org/10.1080/17452759.2024.2440609
Department(s)
Mechanical and Aerospace Engineering
Publication Status
Open Access
Keywords and Phrases
finite element analysis; in situ process monitoring; laser processing; Metal additive manufacturing; sheet feedstock
International Standard Serial Number (ISSN)
1745-2767; 1745-2759
Document Type
Article - Journal
Document Version
Final Version
File Type
text
Language(s)
English
Rights
© 2025 The Authors, All rights reserved.
Publication Date
01 Jan 2025