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Control of the melt pool size is necessary to achieve more homogenous material properties in wire arc additive manufacturing (WAAM). The melt pool size can be measured by camera imaging or temperature field measurement. The paper aims to investigate the feasibility of using a high dynamic range two-colored pyrometric camera (Pyrocam) for melt pool size measurement in a gas metal arc welding–based WAAM process. A set of band-pass filters is identified using spectroscopy analysis to reduce the optical arc emission while the melt pool remains visible. The fusion line is identified in temperature field images, the melt pool size is measured by an automated algorithm, and the results are compared with high-speed camera images. A possible correlation between melt pool size and the grain size is examined.

Measuring the melt pool size in a wire arc additive manufacturing process using a high dynamic range two-colored pyrometric camera