Additive Manufacturing Energy Control for Uniform Melt Pool Formation
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in achieving uniform energy application, leading to non-uniformities in the manufactured component due to varying energy requirements across different locations.
Innovation Solution
The method involves determining an energy application parameter at each addition location based on factors like overlap volume between a virtual geometric shape and the previously formed component, and adjusting the energy delivery accordingly to form a melt pool and consolidate it with the existing component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed amount of energy is applied during additive manufacturing, then the manufacturing process is simple to control, but non-uniformities are produced in the manufactured component due to varying energy requirements at different locations
Solution Approach 1:
The patent applies local quality by determining location-specific energy application parameters based on the geometric shape and orientation at each addition location. The system calculates overlap volumes between the virtual geometric shape and previously formed portions to establish customized energy parameters for each location, ensuring uniform energy distribution despite varying geometric conditions.
Solution Approach 2:
The patent implements preliminary action by pre-determining energy application parameters for each addition location before actual manufacturing. The system calculates the overlap volume and establishes the energy parameter in advance, allowing the energy delivery system to apply the precise amount of energy needed at each location without real-time adjustments during the manufacturing process.
2Manufacturing precision
If energy application parameters are adjusted for each addition location based on overlap volume, then uniformity of the manufactured component is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The patent uses copying by creating a virtual geometric shape that replicates the desired final component geometry. This virtual model is used to calculate overlap volumes at each addition location, allowing the system to determine energy parameters based on the digital replica rather than requiring complex physical measurements during manufacturing.
Solution Approach 2:
The patent replaces mechanical measurement and adjustment systems with computational methods. Instead of using physical gauges or manual adjustments to determine energy parameters, the system uses computer-based calculations of overlap volumes between the virtual geometric shape and previously formed portions to automatically establish energy application parameters.
3Reliability
If the energy amount is increased to ensure adequate consolidation at all locations, then consolidation reliability is improved, but excessive energy causes non-uniformities and material property variations
Solution Approach 1:
The patent applies partial action by delivering energy in controlled amounts specific to each addition location's needs rather than using a uniform excessive energy level throughout. The system calculates the precise energy required for each location based on overlap volume, applying only the necessary amount to achieve adequate consolidation without causing material property variations.
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 enables more precise control over the energy application, reducing variations in the melt pool size and material properties across the component, thereby improving the uniformity and quality of the manufactured component.
Implementation Method 1
delivering, from an energy source and to the addition location, an amount of energy sufficient to form a melt pool of the feedstock material at the addition location
Implementation Method 2
consolidating the melt pool with a previously formed portion of the manufactured component to form an additional portion of the manufactured component
Data Source
AI summary
Methods of additively manufacturing a manufactured component and systems that perform the methods. The methods include determining an energy application parameter at an addition location on a previously formed portion of the manufactured component. The energy application parameter includes an overlap volume between a virtual geometric shape, which is positioned at the addition location, and the previously formed portion of the manufactured component. The methods also include supplying a feedstock material to the addition location. The methods further include delivering, from an energy source and to the addition location, an amount of energy sufficient to form a melt pool of the feedstock material at the addition location. The amount of energy is based, at least in part, on the energy application parameter. The methods also include consolidating the melt pool with a previously formed portion of the manufactured component to form an additional portion of the manufactured component.