Superellipsoid modeling of wire-laser additive manufacturing defects measured by digital image correlation

Abstract: In wire-laser additive manufacturing (WLAM), producing parts with multiple entities requires optimizing both additive and subtractive processes. This involves adjusting positions and integrating machining operations. Geometric defects that occur during the components' deposition can affect subsequent entity production, making real-time measurement crucial. A contactless measuring system is essential to assess geometric deviations without complex post-processing. A comprehensive image stereocorrelation approach addresses this challenge. The produced geometry often has unaccounted features, such as rounded edges and corners. Superellipsoids serve as a versatile modeling tool for representing common geometries in WLAM and assessing dimensional and shape defects. Defined by three scale and two shape parameters, superellipsoids are introduced generally. This modeling tool is then combined with a global image correlation problem. The parameters defining this geometry are identified by minimizing the gray level difference between two images of a part. This approach is demonstrated in a case study, highlighting deviations in WLAM with a parameterized surface and paving the way for geometry updates in computer-aided manufacturing.