In situ elemental analysis and failures detection during additive manufacturing process utilizing laser induced breakdown spectroscopy.

The feasibility of in situ quantitative multielemental analysis and production failures detection by laser induced breakdown spectroscopy (LIBS) has been demonstrated during direct energy deposition process in additive manufacturing. Compact LIBS probe was developed and equipped with the laser cladding head installed at industrial robot for real-time chemical quantitative analysis of key components (Ni, W) during the synthesis of high wear resistant coatings of nickel alloy reinforced with tungsten carbide particles. Owing to non-uniform distribution of tungsten carbide grains in the upper surface layer the only acceptable choice for LIBS sampling was made to the melt pool at growing clad. Laser ablation at powder particles above melt pool was insignificant for LIBS plasma properties due to low intensity and low probability of plasma breakdown at powder particles. No impact of LIBS sampling on cladding process and clad properties was observed according to optical and scanning electron microscopies. The feasibility of in situ LIBS quantitative elemental analysis of key components (tungsten and nickel) has been demonstrated during the cladding process. LIBS analysis results were in good agreement with offline measurements by electron energy dispersive X-ray spectroscopy and X-ray fluorescence spectroscopy. Finally, LIBS technique was demonstrated to be a good tool for real-time detection of cladding process failures (poor laser beam quality, undesirable variation of components concentrations).