A Review of Diagnostics Methodologies for Metal Additive Manufacturing Processes and Products

Additive manufacturing technologies based on metal are evolving into an essential advanced manufacturing tool for constructing prototypes and parts that can lead to complex structures, dissimilar metal-based structures that cannot be constructed using conventional metallurgical techniques. Unlike traditional manufacturing processes, the metal AM processes are unreliable due to variable process parameters and a lack of conventionally acceptable evaluation methods. A thorough understanding of various diagnostic techniques is essential to improve the quality of additively manufactured products and provide reliable feedback on the manufacturing processes for improving the quality of the products. This review summarizes and discusses various ex-situ inspections and in-situ monitoring methods, including electron-based methods, thermal methods, acoustic methods, laser breakdown, and mechanical methods, for metal additive manufacturing.

Automated summary

Metal additive manufacturing technologies are becoming essential for constructing prototypes and parts with complex structures. However, the unreliable nature of metal AM processes due to variable parameters and lack of conventional evaluation methods calls for a thorough understanding of diagnostic techniques to improve product quality and manufacturing processes.