Review of in-situ process monitoring and in-situ metrology for metal additive manufacturing
Open accessAbstract
Lack of assurance of quality with additively manufactured (AM) parts is a key technological barrier that prevents manufacturers from adopting AM technologies, especially for high-value applications where component failure cannot be tolerated. Developments in process control have allowed significant enhancement of AM techniques and marked improvements in surface roughness and material properties, along with a reduction in inter-build variation and the occurrence of embedded material discontinuities. As a result, the exploitation of AM processes continues to accelerate. Unlike established subtractive processes, where in-process monitoring is now commonplace, factory-ready AM processes have not yet incorporated monitoring technologies that allow discontinuities to be detected in process. Researchers have investigated new forms of instrumentation and adaptive approaches which, when integrated, will allow further enhancement to the assurance that can be offered when producing AM components. The state-of-the-art with respect to inspection methodologies compatible with AM processes is explored here. Their suitability for the inspection and identification of typical material discontinuities and failure modes is discussed with the intention of identifying new avenues for research and proposing approaches to integration into future generations of AM systems.
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Powder-based processes are prone to issues of porosity, lack-of-fusion, balling, and cracks, while geometry deviation, shape shrinkage, surface imperfections, layer misalignment, and adhesion issues are the main concerns in the FFF processes.
“Powder-based processes are prone to issues of porosity, lackof-fusion, balling, and cracks [428,430,431], while geometry deviation, shape shrinkage, surface imperfections, layer misalignment, and adhesion issues [432-435] are the main concerns in the FFF processes.”
From A comprehensive review of lunar-based manufacturing and construction (2024) · cites this paper as [428]
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Experimental — accuracy not yet measuredEfficient quality assurance and monitoring technologies to detect the onset of defects and control the printing process are also crucial.
“Efficient quality assurance and monitoring technologies to detect the onset of defects and control the printing process are also crucial [428,429].”
From A comprehensive review of lunar-based manufacturing and construction (2024) · cites this paper as [428]
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Scime, L., & Beuth, J. (2018) · Additive Manufacturing · doi:10.1016/j.addma.2017.11.009 · Cited by 489 · see citing works
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A comprehensive review of lunar-based manufacturing and construction
Azami, M., Kazemi, Z., Moazen, S., Dubé, M., Potvin, M.-J., & Skonieczny, K. (2024) · Progress in Aerospace Sciences · doi:10.1016/j.paerosci.2024.101045 · Cited by 57 · see citing works
Hyperspectral imaging for prediction of surface roughness in laser powder bed fusion
Gerdes, N., Hoff, C., Hermsdorf, J., Kaierle, S., & Overmeyer, L. (2021) · The International Journal of Advanced Manufacturing Technology · doi:10.1007/s00170-021-07274-1 · Cited by 36 · see citing works
- Authors
- Everton, S. K., Hirsch, M., Stravroulakis, P., Leach, R. K., & Clare, A. T.
- Affiliations
- University of Nottingham (GB)
- Corresponding author
- Everton, Sarah K.
- Venue
- Materials & Design
- Publisher
- Elsevier BV
- Published
- 2016-04
- Volume
- 95
- Pages
- 431-445
- ISSN
- 0264-1275 (ISSN-L)
- OpenAlex
- W2250894080
- Cited by
- 1,469
- References
- 102
- Citations by year
- 2026: 134 · 2025: 133 · 2024: 125 · 2023: 152 · 2022: 192 · 2021: 204 · 2020: 181 · 2019: 155 · 2018: 128 · 2017: 48 · 2016: 17
- FWCI
- 102.97
- Type
- journal article
- Language
- en
- Open access
- hybrid
- doi.org
- Locations
- Materials & Design (publishedVersion, cc-by)
- Repository@Nottingham (University of Nottingham) (publishedVersion, other-oa)
- Repository@Nottingham (University of Nottingham) (submittedVersion, cc-by)
- DOAJ (DOAJ: Directory of Open Access Journals) (submittedVersion)
- Nottingham ePrints (University of Nottingham) (submittedVersion, cc-by-nc-nd)
- Funders
- UK Research Centre in Non-Destructive Evaluation (EP/L022125/1)
- In-situ monitoring of component integrity during additive manufacturing using optical coherence tomography (EP/L01713X/1)
- Metrology for precision and additive manufacturing (EP/M008983/1)
- Topics
- Physical Sciences › Engineering › Mechanical Engineering › Additive Manufacturing Materials and Processes
- Physical Sciences › Engineering › Automotive Engineering › Additive Manufacturing and 3D Printing Technologies
- Physical Sciences › Engineering › Mechanical Engineering › Non-Destructive Testing Techniques
- Keywords
- metal additive manufacturing, in-situ process monitoring, in-situ metrology, process control, quality assurance, material discontinuities, failure modes, inspection methods, embedded discontinuities, adaptive process control
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