Real-time acoustic emission monitoring of powder mass flow rate for directed energy deposition

In order to ensure a reliable and repeatable additive manufacturing process, the material delivery rate in the directed energy deposition (DED) process requires in situ monitoring and control. This paper demonstrates acoustic emission (AE) sensing as a method of monitoring the flow of powder feedstock in a powder fed DED process. With minimal calibration, this signal closely correlates to the actual mass flow rate. This article describes the fabricated mass flow monitoring system, documents various conditions in which the actual flow rate deviates from its set value, and details situations that highlight the system's utility. While AE mass flow monitoring is not free of concerns, its features make it an attractive measurement technique in the powder-fed DED process. The work presented here highlights the results obtained and illustrates that accurate monitoring of powder flow in real-time regardless of environmental conditions within the build chamber is possible.