Localized defect frequencies for Laser Metal Deposition processes

Abstract

Laser Metal Deposition (LMD) uses laser energy and powder material to create structures on existing components. It is capable of producing cost-effective multi-material compositions, such as reinforcing metals with ceramic particles for improved wear resistance. However, the use of dissimilar materials often leads to defects, particularly delamination. Previous studies have found a connection between these defects and specific airborne acoustic emissions (AE).

To mitigate the impact of defects, extensive optimization of process parameters and real-time process monitoring are recommended. For AE, precise localization of defects is crucial besides to time- and frequency-resolved information, especially while producing multiple components on a substrate material.

This study evaluates multi-sensor arrays for the localization of delamination defects. The research investigates the influence of localization algorithms and array patterns on the accuracy and reliability of defect localization. Experiments were conducted on a test platform with simulated acoustical events to determine the most suitable localization setup.