List of frequently asked questions about CLAMIR
Below you can find a list of Frequently Asked Questions about CLAMIR, its operation, integration and software.
Feel free to contact us back at sales@clamir.com if you have any additional questions!
CLAMIR operation
Q: How does CLAMIR work?
A: CLAMIR is based in a high-speed infrared camera (1.1 um – 5.0 um) which monitors the geometry of the melt pool, calculates the width, and closes the loop by controlling the laser power to maintain this width constant along the whole process.
Q: What is the benefit of using CLAMIR?
A: The benefit in LMD is an accurate control of the applied power into the part under manufacturing, preventing from an overheating of this part that could eventually lead to stops in the production process; in cladding processes, CLAMIR can help to avoid permanent damages to the substrate material. A side effect is that the dilution rate is kept low.
Q: Does CLAMIR perform an absolute temperature measurement of the melt pool? How does the system handle emissivity of materials?
A: No, CLAMIR operation is not based in an absolute temperature measurement. The dimensional analysis of the geometry is based in the contrast between the melt pool region and the background.
Q: If I use CLAMIR, will I be allowed to make processes using constant laser power?
A: Yes, CLAMIR can also work as a monitoring tool, providing the instantaneous melt pool width measurement during the process made with constant laser power. This is very useful when someone is trying to set-up a complex process or want to monitor areas where certain conditions could lead to fails due to an excess of heat. Another benefit of the monitoring mode is in aerospace applications where most of the manufacturing processes are qualified and no change of the manufacturing parameters is allowed.
Q: Is CLAMIR compatible with the main laser source technologies?
A: Yes, CLAMIR’s performance has been tested with diode, fiber and disk laser sources.
Q: What is the maximum processing time without interruption (for long process runs)?
A: CLAMIR has been proven in high-power LMD continuous processes of hours without saturation or drift problems. Nevertheless, if this effect is detected, CLAMIR can be programmed to perform automatically a 1-pt offset correction periodically under certain conditions (timer, or temperature drift). CLAMIR will take around 500 ms to perform the correction of the offset.
Q: Is there documentation available for the initial set-up and configuration?
A: CLAMIR is supplied with a user manual which includes very detailed information for the initial set-up and configuration of the system.
CLAMIR opto-mechanical integration
Q: How is CLAMIR optically integrated in the L-DED system?
A: CLAMIR is installed in an optical port existing in the laser optics which allows an on-axis observation of the melt pool. It is very important that there is not any optical element in the optical path that blocks the melt pool emission above 1.1 um, as CLAMIR uses the radiation above 1.1 um to control the process.
Q: Is CLAMIR compatible with the main laser optics used in L-DED?
A: Yes, the performance of CLAMIR has been successfully tested with laser optics from the main manufacturers: Trumpf, Laserline, Precitec and Coherent, among others.
Q: How is CLAMIR attached to the optical port?
A: The front part of CLAMIR optics has a C-mount female thread which allows to couple the system to the optical port. In addition, there is a counterthread nut that allows a tight assembly.
Q: Will CLAMIR work well with both 0º & 90º laser configurations?
A: Yes, but it is important that the dichroic mirror has very high reflection (0º) / transmission (90º) in the >1.1 um range so that the melt pool emitted signal reaches the optical port correctly.
Q: How is CLAMIR focused?
A: The lens of CLAMIR allows an adjustment of the focus. In addition, CLAMIR is supplied with a calibration lamp that is used for that purpose.
Q: What is the maximum/minimum melt pool diameter you CLAMIR can monitor?
A: This is a matter of magnification; it will be possible to use alternate lenses in the system to monitor either small or large melt pools.
Q: Can CLAMIR be combined with a visible camera, sharing the same optical port?
A: Yes, it is possible to supply an external dichroic mirror to split the emitted signal into a visible and an infrared channel. NIT can supply this external accessory.
CLAMIR electrical integration
Q: What signal does CLAMIR use to control the laser power?
A: CLAMIR generates an analog signal, 0 – 10 VDC, to control the laser power. This is a standard in the industry for laser power control. The signal can be transmitted using a coaxial cable to avoid loses.
Q: How can I configure the conversion from Power (W) to Volts (VDC) of the control signal?
A: The conversion between Power (W) and Volts (VDC) for the analog output is configured in the CLAMIR Acquisition and Configuration Software.
Q: Where is the connection to the control signal?
A: CLAMIR has a connection box with one female, BNC connector where the control signal can be accessed.
Q: What is the maximum laser power that CLAMIR can control?
A: The maximum laser power that CLAMIR can control is 30 kW. If you need to cover a higher range, let us know.
Q: Is it necessary to have a Laser ON/OFF signal transmitted from the laser power control unit to CLAMIR?
A: No, but it is recommended. If it is not connected, CLAMIR will use image processing methods to determine if the laser is ON or OFF.
CLAMIR process compatibility
Q: Can CLAMIR be used with different powder materials and different flow rates?
A: Yes, CLAMIR’s performance has been tested with different powder material, including SLS360, Inconel 625, Inconel 718 and Tungsten powders, using different flow rates.
Q: What is the maximum/minimum linear speed that CLAMIR can monitor?
A: CLAMIR’s performance has been tested at multiple linear speeds, including EHLA processes.
Q: Can CLAMIR closed-loop feedback control parameters be adjusted?
A: Yes, the user can modify the PID parameters and configure them based in the process’ specifications. These parameters (Kp, Ki, Kd) are modified using the CLAMIR Acquisition and Configuration Software supplied with the system. When delivered, CLAMIR will have default values for these parameters.
Q: Can I store permanently in CLAMIR the configuration parameters for a default process?
A: Yes, a default configuration can be stored permanently inside of CLAMIR flash memory. This configuration will be used per default every time that the system is powered on.
Q: Is it easy to set the system for reference values?
A: Yes. The main parameter to set up is the initial laser power. After the process has started, during the first stages of the manufacturing, there is an option so that CLAMIR automatically calculates the melt pool width reference to use in the process. Alternative, the user can manually set the reference melt pool width to be used during the control and configure when laser power control should start.
CLAMIR software integration
Q: How is CLAMIR connected to the PC?
A: CLAMIR uses a Gigabit Ethernet connection to the PC. The connection is established through a TCP/IP protocol.
Q: Is it necessary a permanent connection between the PC and CLAMIR to ensure a correct operation of CLAMIR?
A: No, CLAMIR can operate as a standalone system.
Q: How is the data logged in the PC?
A: The CLAMIR Acquisition and Configuration SW stores the logged data using a proprietary datafile format (.DAT). The structure of the DAT files is explained in the User Manual to allow the user to develop their own analysis software.
Q: How is the logged data logged visualized in the PC?
A: The Visualization SW supplied with the system allows to open the logged files (DAT format).
Q: Do I need to have connection to CLAMIR to visualize the logged data?
A: No, the Visualization SW does not need a connection to CLAMIR for operation.
Q: What information is logged in the DAT files?
A: All the information related to the process (configuration and set-up parameters), process monitoring (melt-pool width), status of CLAMIR and commanded laser power is stored in the DAT files. The recording of the infrared image is configurable by the user.
Q: Why are the logged DAT files so large? Can I reduce the total size?
A: CLAMIR Acquisition and Configuration SW has several options regarding to the recording of the log files. First, the frequency of the datalogging can be reduced from 1 kHz to 1 Hz. Then, it is also possible to discard the image information and not record it which will have a direct impact in the final file size.
Q: Are there multilingual versions of CLAMIR Acquisition and Configuration SW?
A: Yes. Currently both the SW and user manual are available in English, German, Chinese and Japanese languages.
Q: Are the software updates included in the system, or they need to be purchased separately?
A: All the software updates can be downloaded freely through the exclusive private area of CLAMIR users. The availability of new updates will be communicated via email.
Q: Does CLAMIR allow a deeper level of integration within existing platforms or HMI?
A: Yes, the product includes a DLL for Windows which allows custom software integration with CLAMIR using C++.
