This study presents the development and validation of an in situ monitoring method for the laser direct energy deposition (DED) process, utilizing an integrated optical camera (720 HD, 60 fps) to analyze melt pool imagery. The approach is grounded in an experimental framework employing Taguchi orthogonal arrays, which ensures a stable dataset by controlling process variability and enabling reliable extraction of relevant features. The monitoring system focuses on analyzing brightness distribution regions within the melt pool image, identified as specific clusters that reflect external process conditions. The method emphasizes precise segmentation of the melt pool area, combined with automatic detection and classification of cluster features associated with key process parameters—such as focus distance, the number of deposited layers, powder feed rate, and scanning speed. The main contribution of this work is demonstrating the effectiveness of using an optical camera for DED monitoring, based on an algorithm that processes a set of melt pool identification features through computer vision and machine learning techniques, including Random Forest and HistGradient Boosting, achieving classification accuracies exceeding 95%. By continuously tracking the evolution of these features within a closed-loop control system, the process can be maintained in a stable, defect-free state, effectively preventing the formation of common process defects.
Paringer et al. (Tue,) studied this question.