Online stress monitoring during laser-directed energy deposition based on dynamic contour method
Deformation and cracking caused by internal stress have been a long-standing challenge in the field of metal additive manufacturing. This paper presents a novel method for real-time stress assessment of laser-directed energy deposition (LDED) based on the shrinkage phenomenon of deposition layer – t...
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| Main Authors: | , , , , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Taylor & Francis Group
2025-12-01
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| Series: | Virtual and Physical Prototyping |
| Subjects: | |
| Online Access: | https://www.tandfonline.com/doi/10.1080/17452759.2024.2448543 |
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| Summary: | Deformation and cracking caused by internal stress have been a long-standing challenge in the field of metal additive manufacturing. This paper presents a novel method for real-time stress assessment of laser-directed energy deposition (LDED) based on the shrinkage phenomenon of deposition layer – the Dynamic Contour Method (DCM). It integrates machine vision, three-dimensional reconstruction based on actual morphology, and numerical simulation to calculate rapidly stress development during the LDED process. Meanwhile, a mapping relationship between the surface shrinkage of the deposition layer and stress is established, providing a theoretical basis for the DCM. Regarding the validation of this method, the DCM simulations are compared with the experimentally calibrated thermo-mechanical coupling simulations. The results show a high degree of consistency, demonstrating the feasibility and accuracy of the DCM. This method provides a new digital twin framework for additive manufacturing. |
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| ISSN: | 1745-2759 1745-2767 |