EAAI Journal 2026 Journal Article
High-fidelity imaging of laser-directed energy deposition via a dual-stage strategy of exposure optimization and adaptive enhancement
- Jiazhen Li
- Xingyu Jiang
- Ao Liu
- Shun Liu
- Qingze Tan
- Weijun Liu
- Zhiqiang Tian
The quality of melt pool images is paramount for vision-based in-situ monitoring in laser additive manufacturing (LAM). However, the intense radiation from the melt pool results in sensor oversaturation, which obscures critical process features and compromises defect detection. Whilst current imaging methods can enhance image quality, they suffer from a trade-off between costly hardware and adaptability to dynamic process conditions, impeding practical implementation. This study introduces a novel dual-stage imaging framework that proactively suppresses oversaturation by optimizing exposure time to 65 μs and enhancing algorithms. A Deep-Guided Adaptive Gamma Pool (DGA-Pool) algorithm is employed. This method leverages a lightweight deep learning network to generate a high-quality reference, which guides a rapid, adaptive search for the optimal gamma correction parameter to precisely restore critical details. By employing an asynchronous architecture, the application time is reduced to approximately 0. 113 ms per frame, achieving a real-time effective throughput of approximately 137. 25 frames per second. The proposed framework significantly enhances image contrast and the visibility of key features. In a downstream classification task, the enhanced images enabled the model to achieve a higher accuracy of 95. 37% (compared to an 86. 87% baseline) by focusing on the true physical morphology of the melt pool rather than artifacts from oversaturation and spatter. This work thus presents an effective and real-time imaging methodology, offering a promising machine vision solution for robust quality control and defect detection in LAM.