In-Process Evaluation of Deposition Efficiency in Laser Metal Deposition

Laser Metal Deposition (LMD) is an advanced Additive Manufacturing (AM) technology widely used for metal component fabrication, cladding, and repair. Despite its potential, issues such as geometrical inaccuracies and deposition flaws can significantly affect part quality and process efficiency. Existing optical monitoring approaches mainly focus on geometric features and generally do not provide real-time estimates of deposition efficiency, which is critical for both product performance and resource utilization. Furthermore, evaluating deposition efficiency in industrial settings is often time-consuming and difficult to implement. This preliminary study introduces an innovative in-process methodology for assessing deposition efficiency during multi-track deposition. The approach exploits end-track scan data acquired by a laser line scanning system to estimate the deposited volume and the corresponding deposition efficiency for each track. A validation test on a two-layer sample demonstrates the capability of the method to detect defects induced by partially clogged and non-clogged nozzle conditions. Comparison with metallographic measurements shows an average deviation of 4.3%. By enabling timely identification of powder feeding anomalies and supporting improved powder utilization, the proposed methodology contributes to waste reduction, enhanced process stability, and more sustainable industrial implementation of LMD.