In-situ Monitoring of Direct Energy Deposition via Structured Light System and its Application in Remanufacturing Industry

In-situ Monitoring of Direct Energy Deposition via Structured Light System and its Application in Remanufacturing Industry | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article In-situ Monitoring of Direct Energy Deposition via Structured Light System and its Application in Remanufacturing Industry Xiao Zhang, Weijun Shen, Vignesh Suresh, Jakob Hamilton, Li-Hsin Yeh, and 6 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-278338/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 4 You are reading this latest preprint version Abstract The Direct Energy Deposition (DED) process utilizes laser energy to melt metal powders and deposit them on the substrate layer to manufacture complex metal parts. This study was applied as a remanufacturing and repair process to fix used parts, which reduced unnecessary waste in the manufacturing industry. However, there could be defects generated during the repair, such as porosity or bumpy morphological defects. Traditionally the operator would use a design of experiment (DOE) or simulation method to understand the printing parameters’ influence on the printed part. There are several influential factors: laser power, scanning speed, powder feeding rate, and standoff distance. Each DED machine has a different setup in practice, which results in some uncertainties for the printing results. For example, the nozzle diameter and laser type could be varied in different DED machines. Thus, it was hypothesized that a repair could be more effective if the printing process could be monitored in real-time. In this study, a structured light system (SLS) was used to capture the printing process’s layer-wise information. The SLS system is capable of performing 3D surface scanning with a high-resolution of 10 µm. To determine how much material needs to be deposited, given the initial scanning of the part and allowing the real-time observation of each layer’s information. Once a defect was found in-situ, the DED machine (hybrid machine) would change the tool and remove the flawed layer. After the repair, the nondestructive approach computed tomography (CT) was applied to examine its interior features. In this research, a DED machine using 316L stainless steel was used to perform the repairing process to demonstrate its effectiveness. The lab-built SLS system was used to capture each layer’s information, and CT data was provided for the quality evaluation. The novel manufacturing approach could improve the DED repair quality, reduce the repair time, and promote repair automation. In the future, it has a great potential to be used in the manufacturing industry to repair used parts and avoid the extra cost involved in buying a new part. Mechanical Engineering direct energy deposition in-situ monitoring structured light system remanufacturing Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Full Text Due to technical limitations, full-text HTML conversion of this manuscript could not be completed. However, the latest manuscript can be downloaded and accessed as a PDF. Cite Share Download PDF Status: Under Review Version 1 posted Reviews received at journal 29 Mar, 2021 Editor assigned by journal 28 Feb, 2021 Reviewers invited by journal 28 Feb, 2021 First submitted to journal 25 Feb, 2021 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-278338","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":14293113,"identity":"4ee9ce74-9ff9-4b05-9e12-a51e032291f8","order_by":0,"name":"Xiao Zhang","email":"","orcid":"","institution":"Iowa State University","correspondingAuthor":false,"prefix":"","firstName":"Xiao","middleName":"","lastName":"Zhang","suffix":""},{"id":14293114,"identity":"66ff8e5b-4bd0-44b1-bb6f-4c8f4cb6a18c","order_by":1,"name":"Weijun Shen","email":"","orcid":"","institution":"Iowa State University","correspondingAuthor":false,"prefix":"","firstName":"Weijun","middleName":"","lastName":"Shen","suffix":""},{"id":14293115,"identity":"2e9d0282-2219-4466-bcb9-a94c43276ba9","order_by":2,"name":"Vignesh Suresh","email":"","orcid":"","institution":"Iowa State University","correspondingAuthor":false,"prefix":"","firstName":"Vignesh","middleName":"","lastName":"Suresh","suffix":""},{"id":14293116,"identity":"c00c477d-9cc5-4cce-92d9-853556764cf1","order_by":3,"name":"Jakob Hamilton","email":"","orcid":"","institution":"Rochester Institute of Technology","correspondingAuthor":false,"prefix":"","firstName":"Jakob","middleName":"","lastName":"Hamilton","suffix":""},{"id":14293117,"identity":"386e836e-6e39-4988-a2af-7b31457bdda9","order_by":4,"name":"Li-Hsin Yeh","email":"","orcid":"","institution":"Iowa State University","correspondingAuthor":false,"prefix":"","firstName":"Li-Hsin","middleName":"","lastName":"Yeh","suffix":""},{"id":14293118,"identity":"b7e83671-dde8-4b2a-9ac3-33d94fe72535","order_by":5,"name":"Xuepeng Jiang","email":"","orcid":"","institution":"Iowa State University","correspondingAuthor":false,"prefix":"","firstName":"Xuepeng","middleName":"","lastName":"Jiang","suffix":""},{"id":14293119,"identity":"175bdcc3-f952-4e7d-8637-b84cde62858e","order_by":6,"name":"Zhan Zhang","email":"","orcid":"","institution":"Iowa State University","correspondingAuthor":false,"prefix":"","firstName":"Zhan","middleName":"","lastName":"Zhang","suffix":""},{"id":14293120,"identity":"b10b9c27-d183-4238-9316-7920185ec44a","order_by":7,"name":"Qing Li","email":"","orcid":"","institution":"Iowa State University","correspondingAuthor":false,"prefix":"","firstName":"Qing","middleName":"","lastName":"Li","suffix":""},{"id":14293121,"identity":"7e6e18dc-6537-47a1-996c-18203d660bf3","order_by":8,"name":"Beiwen Li","email":"","orcid":"","institution":"Iowa State University","correspondingAuthor":false,"prefix":"","firstName":"Beiwen","middleName":"","lastName":"Li","suffix":""},{"id":14293122,"identity":"7650e607-0bfc-459a-b925-fea1ec24410e","order_by":9,"name":"Iris V. 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25","display":"","copyAsset":false,"role":"figure","size":91530,"visible":true,"origin":"","legend":"Surface data of Sample 2 from CT and SLS","description":"","filename":"25.png","url":"https://assets-eu.researchsquare.com/files/rs-278338/v1/7fdb6561e92f009abc167245.png"},{"id":6673945,"identity":"1da3de1c-d924-463e-8ab1-6ff5a6a42f2b","added_by":"auto","created_at":"2021-03-06 15:21:56","extension":"png","order_by":26,"title":"Figure 26","display":"","copyAsset":false,"role":"figure","size":98413,"visible":true,"origin":"","legend":"Histograms of the mean distance from C2M and M3C2 results, (a-c) the histograms of C2M results for Sample 1- 3, (d-f) the histograms of M3C2 results for Sample 1- 3","description":"","filename":"26.png","url":"https://assets-eu.researchsquare.com/files/rs-278338/v1/44aab0eccc59c3a1c9874eca.png"},{"id":6675143,"identity":"32207460-b7ee-4089-b90b-4e6135fcdb8a","added_by":"auto","created_at":"2021-03-06 15:27:57","extension":"png","order_by":27,"title":"Figure 27","display":"","copyAsset":false,"role":"figure","size":73246,"visible":true,"origin":"","legend":"Scatterplot showing the correlation of two kinds of datasets for a Sample 1, b sample 2, c sample3\n4 Conclusion\n","description":"","filename":"27.png","url":"https://assets-eu.researchsquare.com/files/rs-278338/v1/f204197c8857bec77af7cf23.png"},{"id":13599922,"identity":"57d5416d-3e98-4d49-9bf8-facce7c81146","added_by":"auto","created_at":"2021-09-17 05:41:32","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1807759,"visible":true,"origin":"","legend":"","description":"","filename":"Manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-278338/v1_covered.pdf"},{"id":6676156,"identity":"5a7e3d0a-7db0-4947-b0b6-eab6c1613794","added_by":"auto","created_at":"2021-03-06 15:34:00","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1660476,"visible":true,"origin":"","legend":"","description":"","filename":"Manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-278338/v1_stamped.pdf"}],"financialInterests":"","formattedTitle":"In-situ Monitoring of Direct Energy Deposition via Structured Light System and its Application in Remanufacturing Industry","fulltext":[{"header":"Full Text","content":"Due to technical limitations, full-text HTML conversion of this manuscript could not be completed. However, the latest manuscript can be downloaded and \u003ca href='/article/rs-278338/latest.pdf' target='_blank'\u003e accessed as a PDF.\u003c/a\u003e"}],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":false,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"direct energy deposition, in-situ monitoring, structured light system, remanufacturing","lastPublishedDoi":"10.21203/rs.3.rs-278338/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-278338/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThe Direct Energy Deposition (DED) process utilizes laser energy to melt metal powders and deposit them on the substrate layer to manufacture complex metal parts. This study was applied as a remanufacturing and repair process to fix used parts, which reduced unnecessary waste in the manufacturing industry. However, there could be defects generated during the repair, such as porosity or bumpy morphological defects. Traditionally the operator would use a design of experiment (DOE) or simulation method to understand the printing parameters\u0026rsquo; influence on the printed part. There are several influential factors: laser power, scanning speed, powder feeding rate, and standoff distance. Each DED machine has a different setup in practice, which results in some uncertainties for the printing results. For example, the nozzle diameter and laser type could be varied in different DED machines. Thus, it was hypothesized that a repair could be more effective if the printing process could be monitored in real-time. In this study, a structured light system (SLS) was used to capture the printing process\u0026rsquo;s layer-wise information. The SLS system is capable of performing 3D surface scanning with a high-resolution of 10 \u0026micro;m. To determine how much material needs to be deposited, given the initial scanning of the part and allowing the real-time observation of each layer\u0026rsquo;s information. Once a defect was found in-situ, the DED machine (hybrid machine) would change the tool and remove the flawed layer. After the repair, the nondestructive approach computed tomography (CT) was applied to examine its interior features. In this research, a DED machine using 316L stainless steel was used to perform the repairing process to demonstrate its effectiveness. The lab-built SLS system was used to capture each layer\u0026rsquo;s information, and CT data was provided for the quality evaluation. The novel manufacturing approach could improve the DED repair quality, reduce the repair time, and promote repair automation. In the future, it has a great potential to be used in the manufacturing industry to repair used parts and avoid the extra cost involved in buying a new part.\u003c/p\u003e","manuscriptTitle":"In-situ Monitoring of Direct Energy Deposition via Structured Light System and its Application in Remanufacturing Industry","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2021-03-06 15:21:53","doi":"10.21203/rs.3.rs-278338/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"editorInvitedReview","content":"","date":"2021-03-30T00:00:00+00:00","index":0,"fulltext":""},{"type":"editorAssigned","content":"","date":"2021-03-01T00:00:00+00:00","index":"","fulltext":""},{"type":"reviewersInvited","content":"","date":"2021-03-01T00:00:00+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2021-02-25T09:53:22+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"dfc398d1-3ff8-4cee-af68-e1482357ecae","owner":[],"postedDate":"March 6th, 2021","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[{"id":2790719,"name":"Mechanical Engineering"}],"tags":[],"updatedAt":"2021-06-10T15:51:20+00:00","versionOfRecord":[],"versionCreatedAt":"2021-03-06 15:21:53","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-278338","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-278338","identity":"rs-278338","version":["v1"]},"buildId":"_2-kVJe1T_tPrBINL-cwx","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}