Process Monitoring and Defect Detection of Additive Manufacturing Using Inline Coherent Imaging

With applications ranging from aerospace to biomedicine, additive manufacturing (AM) has been revolutionizing the manufacturing industry. The ability of additive techniques, such as selective laser melting (SLM), to create fully functional, geometrically complex, and unique parts out of high strength materials is of great interest. Unfortunately, despite numerous advantages afforded by this technology, its widespread adoption is hindered by a lack of on-line, real time feedback control and quality assurance techniques. In this thesis, inline coherent imaging (ICI), a broadband, spatially coherent imaging technique, is used to observe the SLM process in 15 - 45 $\mu m$ 316L stainless steel. Imaging of both single and multilayer builds is performed at a rate of 200 $kHz$, with a resolution of tens of microns, and a high dynamic range rendering it impervious to blinding from the process beam. This allows imaging before, during, and after laser processing to observe changes in the morphology and stability of the melt. Galvanometer-based scanning of the imaging beam relative to the process beam during the creation of single tracks is used to gain a unique perspective of the SLM process that has been so far unobservable by other monitoring techniques. Single track processing is also used to investigate the possibility of a preliminary feedback control parameter based on the process beam power, through imaging with both coaxial and 100 $\mu m$ offset alignment with respect to the process beam. The 100 $\mu m$ offset improved imaging by increasing the number of bright A-lines (i.e. with signal greater than the 10 $dB$ noise floor) by 300\%. The overlap between adjacent tracks in a single layer is imaged to detect characteristic fault signatures. Full multilayer builds are carried out and the resultant ICI images are used to detect defects in the finished part and improve upon the initial design of the build system. Damage to the recoater blade is assessed using powder layer scans acquired during a 3D build. The ability of ICI to monitor SLM processes at such high rates with high resolution offers extraordinary potential for future advances in on-line feedback control of additive manufacturing.

ADVANCED ISLANDING DETECTION METHODS FOR SINGLE PHASE GRID CONNECTED PV INVERTERS

Due to the growing concerns associated with fossil fuels, emphasis has been placed on clean and sustainable energy generation. This has resulted in the increase in Photovoltaics (PV) units being integrated into the utility system. The integration of PV units has raised some concerns for utility power systems, including the consequences of failing to detect islanding. Numerous methods for islanding detection have been introduced in literature. They can be categorized into local methods and remote methods. The local methods are categorically divided into passive and active methods. Active methods generally have smaller Non-Detection Zone (NDZ) but the injecting disturbances will slightly degrade the power quality and reliability of the power system. Slip Mode Frequency Shift Islanding Detection Method (SMS IDM) is an active method that uses positive feedback for islanding detection. In this method, the phase angle of the converter is controlled to have a sinusoidal function of the deviation of the Point of Common Coupling (PCC) voltage frequency from the nominal grid frequency. This method has a non-detection zone which means it fails to detect islanding for specific local load conditions. If the SMS IDM employs a different function other than the sinusoidal function for drifting the phase angle of the inverter, its non-detection zone could be smaller. In addition, Advanced Slip Mode Frequency Shift Islanding Detection Method (Advanced SMS IDM), which has been introduced in this thesis, eliminates the non-detection zone of the SMS IDM. In this method the parameters of SMS IDM change based on the local load impedance value. Moreover, the stability of the system is investigated by developing the dynamical equations of the system for two operation modes; grid connected and islanded mode. It is mathematically proven that for some loading conditions the nominal frequency is an unstable point and the operation frequency slides to another stable point, while for other loading conditions the nominal frequency is the only stable point of the system upon islanding occurring. Simulation and experimental results show the accuracy of the proposed methods in detection of islanding and verify the validity of the mathematical analysis.