Compared with powder metallurgy, centrifugal casting, jet molding, and other technologies, Laser Melting Deposition (LMD) stands out as an advanced additive manufacturing technology that provides substantial advantages in the melt forming of functional gradient materials and composites. However, when high-temperature and high-speed laser energy is applied, the resulting materials are susceptible to porosity, which restricts their extensive use in fatigue-sensitive applications such as turbine engine blades, engine connecting rods, gears, and suspension system components. Since fatigue cracks generally originate near pore defects or at stress concentration points, it is crucial to investigate evaluation methods for pore defects and stress concentration in LMD applications. This study examines the effect of pore defects on stress concentration in LMD-manufactured AlSi10Mg using the crystal plasticity finite element method and proposes a stress concentration coefficient characterization approach that considers pore size, morphology, and location. The simulation results indicate a competitive mechanism between pores and grains, where the larger entity dominates. Regarding the influence of aspect ratio on stress concentration, as the aspect ratio decreases along the stress direction, the stress concentration increases significantly. When pores are just emerging from the surface (s/r = 1), the stress concentration caused by the pore reaches its maximum, posing the highest risk of material failure. To assess the extent to which the aspect ratio, position, and size of pores affect stress concentration, a statistical correlation analysis of these variables was conducted.

A monocular deflectometric system comprises a camera and a screen that collaboratively facilitate the reconstruction of a specular surface under test (SUT). This paper presents a methodology for solving the slope distribution of the SUT utilizing pose estimation derived from reflections, based on vision ray calibration (VRC). Initially recorded by the camera, an assisted flat mirror in different postures reflects the patterns displayed by a screen maintained in a constant posture. The system undergoes a calibration based on the VRC to ascertain the vision ray distribution of the camera and the spatial relationship between the camera and the screen. Subsequently, the camera records the reflected patterns by the SUT, which remains in a constant posture while the screen is adjusted to multiple postures. Utilizing the VRC, the vision ray distribution among several postures of the screen and the SUT is calibrated. Following this, an iterative integrated calibration is performed, employing the calibration results from the preceding separate calibrations as initial parameters. The integrated calibration amalgamates the cost functions from the separate calibrations with the intersection of lines in Plücker space. Ultimately, the results from the integrated calibration yield the slope distribution of the SUT, enabling an integral reconstruction. In both the numeric simulations and actual measurements, the integrated calibration significantly enhances the accuracy of the reconstructions when compared to the reconstructions with the separate calibrations.