Towards the improvement of high-speed laser powder bed fusion using aligned datasets obtained from process monitoring based on photodiode signal variation and post-process X-ray computed tomography

Laser powder bed fusion of metals offers important advantages for several industrial applications. Research work is needed to improve the production rates while reducing the likelihood of defects compromising part quality. It is feasible to improve production rates by fabricating parts with thicker layers, but this often leads to an increased presence of flaws. This work focuses on evaluating the potential of employing real-time monitoring data gathered by means of photodiodes for enhancing high-speed LPBF. Potential sites of defects are compared to actual porosities measured via X-ray computed tomography by applying a methodology that guarantees an accurate alignment and comparison considering part shrinkage and distortions.