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<p>The additive manufacturing of thin-walled components is key to producing complex, high-value hollow designs, particularly in the aerospace industry. To master the fabrication of such parts and limit defects that compromise quality, in situ process monitoring is essential. This work implements an off-axis infrared camera to track thermal behavior during LP-DED manufacturing of 316L single-bead walls. The solidification parameters such as the cooling rate, thermal gradient, and solidification rate were extracted from the thermal images and correlated with the microstructural observations. Although trends were identified between process parameters (laser power and scanning speed) and thermal or microstructural characteristics, some of these relationships diverged from expectations in the literature. Geometrical defects, including stacking irregularities and surface roughness, were found to disrupt heat flow, leading to heterogeneous grain morphologies and local alterations in thermal measurements. These findings emphasize the need to account for geometrical defects to ensure reliable thermal monitoring and effective process control. In addition to highlighting the strong influence of geometrical defects, this study demonstrates the potential of in situ IR-based monitoring to predict the microstructure in LP-DED through a comprehensive experimental methodology.</p>

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Impact of geometrical defects on solidification behavior and microstructure in 316L single-bead walls produced by LP-DED: an in situ IR thermography approach

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年5月20日

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  • Lilou de Peindray d’Ambelle,
  • Kamel Moussaoui,
  • Catherine Mabru

摘要

The additive manufacturing of thin-walled components is key to producing complex, high-value hollow designs, particularly in the aerospace industry. To master the fabrication of such parts and limit defects that compromise quality, in situ process monitoring is essential. This work implements an off-axis infrared camera to track thermal behavior during LP-DED manufacturing of 316L single-bead walls. The solidification parameters such as the cooling rate, thermal gradient, and solidification rate were extracted from the thermal images and correlated with the microstructural observations. Although trends were identified between process parameters (laser power and scanning speed) and thermal or microstructural characteristics, some of these relationships diverged from expectations in the literature. Geometrical defects, including stacking irregularities and surface roughness, were found to disrupt heat flow, leading to heterogeneous grain morphologies and local alterations in thermal measurements. These findings emphasize the need to account for geometrical defects to ensure reliable thermal monitoring and effective process control. In addition to highlighting the strong influence of geometrical defects, this study demonstrates the potential of in situ IR-based monitoring to predict the microstructure in LP-DED through a comprehensive experimental methodology.