Theses and Dissertations

ORCID

0009-0009-2469-7256

Advisor

Priddy, Matthew

Committee Member

Betts, Jeffery

Committee Member

Barrett, Christopher

Date of Degree

8-12-2026

Original embargo terms

Visible MSU Only 2 Years

Document Type

Graduate Thesis - Campus Access Only

Major

Mechanical Engineering

Degree Name

Master of Science (M.S.)

College

James Worth Bagley College of Engineering

Department

Michael W. Hall School of Mechanical Engineering

Abstract

Wire-arc directed energy deposition (arc-DED) is a metal additive manufacturing process that uses robotic welding to fabricate near-net-shape parts at high deposition rates. This transient, layer-by-layer process yields parts with a complex thermal history that impacts part quality and complicates qualification. In-situ non-contact thermal monitoring provides a non-destructive approach to monitor process conditions and improve the arc-DED process. However, non contact temperature measurement in arc-DED is challenging due to changing surface conditions, dynamic heating and cooling, and varying emissivity. In this study, measurement accuracy of IR non-contact monitoring methods such as spot pyrometers and IR cameras was evaluated through comparison with welded thermocouples. An emissivity estimation and correction methodology was also developed to improve measurement accuracy across various thermal conditions. The accuracy of non-contact measurements was quantified using average difference and normalized error and shows that the proposed methodology successfully improves the accuracy of in-situ non-contact temperature measurement.

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