Study of innovative solutions to improve the quality of metallic components manufactured by additive manufacturing technologies

In this thesis work, I developed an image processing methodology that was implemented in combination with a coaxial optical system in order to study the melt pool geometry created during the manufacture of components or coatings using the L-DED process. In addition, I developed a cost-effective, flexible and easy-to-use optical monitoring system called 'High resolution-optical tomography', which was implemented to detect geometric distortions occurring during the L-PBF process. As far as the thermal field is concerned, I implemented a preliminary thermal monitoring methodology on the L-PBF machine in order to investigate defects such as local overheating, thus geometrical distortions in the final part, and a lack of melting by monitoring the temperature profile over the whole slice area. Finally, the monitoring systems and methodologies developed were applied to several case studies, presented in the final chapter of the thesis, in order to ensure the high quality of the produced component without additional expensive and time-consuming inspections and to verify the stability of the process in-situ and in real-time.