Guest seminar by Dr Paul Hooper: In-situ monitoring for additive manufacturing: towards qualify-as-you-build

Dr Paul Hooper

In-situ monitoring for additive manufacturing: towards qualify-as-you-build

Guest Speaker: Dr. Paul Hooper

Abstract: Additive manufacturing (AM) processes build up components on a point-by-point, layer-by-layer basis. This gives engineers unprecedented levels of design freedom. However, with this approach comes defects. Process parameters, part geometry, scan strategy and material quality all influence the fusion of material on that same point-by-point basis. In-situ process monitoring tools can give insight into how these factors influence component quality and provide opportunities for improved process control. Inspection for quality control and part qualification can also be performed at the same time, reducing the need for costly post-build inspections.

This talk will detail the development 3 in-situ monitoring systems for laser powder bed fusion: a high-speed coaxial temperature monitoring system, an illuminated high-speed microscope system and a global IR camera system. Results showing the influence of machine problems on the in-situ data and part quality will be presented. Opportunities and challenges for in-situ monitoring of AM processes will also be discussed.

Biography: Paul Hooper is a Research Fellow in the Mechanics of Materials Group in the Department of Mechanical Engineering at Imperial College London. He research focuses on additive manufacturing (AM) and he leads industry-funded projects focusing on certification of AM components. His specific interests include in-situ process monitoring, process-microstructure-performance relationships, simulation of AM processes, design for AM and new process development. He also has interests in high-strain rate material behaviour and structural integrity. He has authored 30 journal publications, has an h-index of 15 and has one patent.