Monitoring of Laser Powder Bed Fusion by Acoustic Emission: Investigation of Single Tracks and Layers

Quality concerns in laser powder bed fusion (L-PBF) include porosity, residual stresses and deformations during processing. Single tracks are the fundamental building blocks in L-PBF and their shape and geometry influence subsequent porosity in 3D L-PBF parts. The morphology of single tracks depends primarily on process parameters. The purpose of this paper is to demonstrate an approach to acoustic emission (AE) online monitoring of the L-PBF process for indirect defect analysis. This is demonstrated through the monitoring of single tracks without powder, with powder and in layers. Gas-borne AE signals in the frequency range of 2–20 kHz were sampled using a microphone placed inside the build chamber of a L-PBF machine. The single track geometry and shape at different powder thickness values and laser powers were studied together with the corresponding acoustic signals. Analysis of the acoustic signals allowed for the identification of characteristic amplitudes and frequencies, with promising results that support its use as a complementary method for in-situ monitoring and real-time defect detection in L-PBF. This work proves the capability to directly detect the balling effect that strongly affects the formation of porosity in L-PBF parts by AE monitoring.