Acoustic Wave Temperature Monitoring in Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing (AM) technologies lack sufficient process control, particularly in monitoring surface temperature, molten build volume, and local surface roughness, leading to potential defects such as microscopic pores that are difficult to detect until post-processing, hindering the ability to ensure quality during the additive process.
Innovation Solution
The use of acoustic waves generated by a pulsed laser to monitor temperature and morphology in real-time, allowing for non-intrusive, non-damaging characterization of material properties, enabling corrective actions before adding subsequent layers, through a system comprising an energy source, acoustic wave generator, detector, and controller to adjust processing parameters based on detected changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional additive manufacturing processes are used without real-time monitoring, then the manufacturing process is simpler and faster, but the quality control is insufficient and defects are hard to detect
Solution Approach 1:
An acoustic wave acts as an intermediary carrier to transmit temperature information from the processing zone to the detector. The acoustic wave properties (speed, attenuation) change in response to temperature variations, enabling indirect but accurate temperature measurement without direct contact with the molten material, thus improving quality control while maintaining relatively simple device structure
Solution Approach 2:
The patent replaces traditional mechanical or contact-based temperature measurement methods with acoustic wave-based measurement. By using acoustic waves that propagate through the material and whose properties are temperature-dependent, the system achieves non-contact, real-time temperature monitoring, thereby improving manufacturing precision without significantly increasing device complexity
2Measurement precision
If real-time temperature monitoring is implemented using acoustic waves, then the temperature measurement accuracy is improved, but the device complexity increases
Solution Approach 1:
The acoustic wave generation system serves multiple functions: it generates the acoustic wave for measurement, and the same system can be used for material processing. This multi-functionality reduces the need for separate dedicated measurement devices, thereby improving temperature measurement accuracy without proportionally increasing overall system complexity
Solution Approach 2:
The material itself serves as the transmission medium for the acoustic wave. The acoustic wave propagates through the material being processed, and the material's own acoustic properties (which are temperature-dependent) provide the measurement signal. This self-service approach eliminates the need for external sensors or transducers in contact with the material, improving measurement accuracy while keeping the system relatively simple
3Reliability
If acoustic wave measurement is used to monitor temperature, then the non-intrusive measurement is achieved, but the measurement system becomes more complex
Solution Approach 1:
The acoustic wave serves as an intermediary that carries temperature information without requiring direct contact between the measurement system and the material. The wave propagates through the material, interacting with its thermal properties, and conveys this information to the detector, enabling reliable non-intrusive measurement while maintaining relatively simple detection hardware
Solution Approach 2:
The patent replaces mechanical contact-based measurement systems with acoustic wave-based measurement. By using the propagation characteristics of acoustic waves (speed, attenuation) that are sensitive to temperature, the system achieves non-intrusive measurement without the complexity of mechanical sensors, transducers, or direct contact interfaces
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach provides real-time, in-line monitoring and remediation of material processing, reducing defects and enabling 'certify as you build' manufacturing by accurately characterizing temperature and morphology, ensuring higher quality and reducing resource waste.
Implementation Method 1
the speed of acoustic waves passing through the material changes as a function of temperature
Implementation Method 2
exciting a first acoustic wave in the material
Data Source
AI summary
Under one aspect, a method of processing a material includes heating a region of the material with a first energy source; exciting an acoustic wave in the material; and transmitting the acoustic wave through the heated region, the heated region changing at least one property of the acoustic wave. The method also can include detecting the change in at least one property of the acoustic wave; characterizing a temperature of the material in the heated region based on the detected change in at least one property of the acoustic wave; and comparing the characterized temperature of the material in the heated region to a threshold. The method further can include, based on the characterized temperature of the material in the heated region being less than the threshold or being above the threshold for an insufficient amount of time, modifying a property of the heated region with a second energy source.