Online Characterization of Internal Stress in Aluminum Alloys During Laser-Directed Energy Deposition
In laser-directed energy deposition (LDED) additive manufacturing, stress-induced deformation and cracking often occur unexpectedly, and, once initiated, they are difficult to remedy. To address this issue, we previously proposed the Dynamic Counter Method (DCM), which monitors internal stress based...
Saved in:
| Main Authors: | , , , , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2025-04-01
|
| Series: | Sensors |
| Subjects: | |
| Online Access: | https://www.mdpi.com/1424-8220/25/8/2584 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1850180825635618816 |
|---|---|
| author | Yi Lu Jian Dong Wenbo Li Chen Wang Rongqi Shen Di Jiang Yang Yi Bin Wu Guifang Sun Yongkang Zhang |
| author_facet | Yi Lu Jian Dong Wenbo Li Chen Wang Rongqi Shen Di Jiang Yang Yi Bin Wu Guifang Sun Yongkang Zhang |
| author_sort | Yi Lu |
| collection | DOAJ |
| description | In laser-directed energy deposition (LDED) additive manufacturing, stress-induced deformation and cracking often occur unexpectedly, and, once initiated, they are difficult to remedy. To address this issue, we previously proposed the Dynamic Counter Method (DCM), which monitors internal stress based on deposition layer shrinkage, enabling real-time stress monitoring without damaging the component. To validate this method, we used AlSi10Mg material, which has a low melting point and high reflectivity, and developed a high-precision segmentation network based on DeeplabV3+ to test its ability to measure shrinkage in high-exposure images. Using a real-time reconstruction model, stress calculations were performed with DCM and thermal–mechanical coupling simulations, and the results were validated through XRD residual stress testing to confirm DCM’s accuracy in calculating internal stress in aluminum alloys. The results show that the DeeplabV3+ segmentation network accurately extracted deposition-layer contours and shrinkage information. Furthermore, DCM and thermal–mechanical coupling simulations showed good consistency in residual stress distribution, with all results falling within the experimental error range. In terms of stress evolution trends, DCM was also effective in predicting stress variations. Based on these findings, two loading strategies were proposed, and, for the first time, DCM’s application in online stress monitoring of large LDED components was validated, offering potential solutions for stress monitoring in large-scale assemblies. |
| format | Article |
| id | doaj-art-883962d5dbf24deb85a0ee0beee975d7 |
| institution | OA Journals |
| issn | 1424-8220 |
| language | English |
| publishDate | 2025-04-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Sensors |
| spelling | doaj-art-883962d5dbf24deb85a0ee0beee975d72025-08-20T02:18:01ZengMDPI AGSensors1424-82202025-04-01258258410.3390/s25082584Online Characterization of Internal Stress in Aluminum Alloys During Laser-Directed Energy DepositionYi Lu0Jian Dong1Wenbo Li2Chen Wang3Rongqi Shen4Di Jiang5Yang Yi6Bin Wu7Guifang Sun8Yongkang Zhang9College of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing 210037, ChinaCollege of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing 210037, ChinaCollege of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing 210037, ChinaCollege of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing 210037, ChinaCollege of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing 210037, ChinaCollege of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing 210037, ChinaCollege of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing 210037, ChinaCollege of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing 210037, ChinaSchool of Mechanical Engineering, Southeast University, Nanjing 211189, ChinaSchool of Electrical and Mechanical Engineering, Guangdong University of Technology, Waihuanxi Road 100, Guangzhou 510006, ChinaIn laser-directed energy deposition (LDED) additive manufacturing, stress-induced deformation and cracking often occur unexpectedly, and, once initiated, they are difficult to remedy. To address this issue, we previously proposed the Dynamic Counter Method (DCM), which monitors internal stress based on deposition layer shrinkage, enabling real-time stress monitoring without damaging the component. To validate this method, we used AlSi10Mg material, which has a low melting point and high reflectivity, and developed a high-precision segmentation network based on DeeplabV3+ to test its ability to measure shrinkage in high-exposure images. Using a real-time reconstruction model, stress calculations were performed with DCM and thermal–mechanical coupling simulations, and the results were validated through XRD residual stress testing to confirm DCM’s accuracy in calculating internal stress in aluminum alloys. The results show that the DeeplabV3+ segmentation network accurately extracted deposition-layer contours and shrinkage information. Furthermore, DCM and thermal–mechanical coupling simulations showed good consistency in residual stress distribution, with all results falling within the experimental error range. In terms of stress evolution trends, DCM was also effective in predicting stress variations. Based on these findings, two loading strategies were proposed, and, for the first time, DCM’s application in online stress monitoring of large LDED components was validated, offering potential solutions for stress monitoring in large-scale assemblies.https://www.mdpi.com/1424-8220/25/8/2584laser-directed energy depositionnumerical simulationresidual stressonline monitoringmachine vision |
| spellingShingle | Yi Lu Jian Dong Wenbo Li Chen Wang Rongqi Shen Di Jiang Yang Yi Bin Wu Guifang Sun Yongkang Zhang Online Characterization of Internal Stress in Aluminum Alloys During Laser-Directed Energy Deposition Sensors laser-directed energy deposition numerical simulation residual stress online monitoring machine vision |
| title | Online Characterization of Internal Stress in Aluminum Alloys During Laser-Directed Energy Deposition |
| title_full | Online Characterization of Internal Stress in Aluminum Alloys During Laser-Directed Energy Deposition |
| title_fullStr | Online Characterization of Internal Stress in Aluminum Alloys During Laser-Directed Energy Deposition |
| title_full_unstemmed | Online Characterization of Internal Stress in Aluminum Alloys During Laser-Directed Energy Deposition |
| title_short | Online Characterization of Internal Stress in Aluminum Alloys During Laser-Directed Energy Deposition |
| title_sort | online characterization of internal stress in aluminum alloys during laser directed energy deposition |
| topic | laser-directed energy deposition numerical simulation residual stress online monitoring machine vision |
| url | https://www.mdpi.com/1424-8220/25/8/2584 |
| work_keys_str_mv | AT yilu onlinecharacterizationofinternalstressinaluminumalloysduringlaserdirectedenergydeposition AT jiandong onlinecharacterizationofinternalstressinaluminumalloysduringlaserdirectedenergydeposition AT wenboli onlinecharacterizationofinternalstressinaluminumalloysduringlaserdirectedenergydeposition AT chenwang onlinecharacterizationofinternalstressinaluminumalloysduringlaserdirectedenergydeposition AT rongqishen onlinecharacterizationofinternalstressinaluminumalloysduringlaserdirectedenergydeposition AT dijiang onlinecharacterizationofinternalstressinaluminumalloysduringlaserdirectedenergydeposition AT yangyi onlinecharacterizationofinternalstressinaluminumalloysduringlaserdirectedenergydeposition AT binwu onlinecharacterizationofinternalstressinaluminumalloysduringlaserdirectedenergydeposition AT guifangsun onlinecharacterizationofinternalstressinaluminumalloysduringlaserdirectedenergydeposition AT yongkangzhang onlinecharacterizationofinternalstressinaluminumalloysduringlaserdirectedenergydeposition |