Additive Manufacturing Energy Control for Uniform Melt Pool Formation
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Solution Overview
Problem
Additive manufacturing processes often result in non-uniformities due to inconsistent energy application, leading to variations in melt pool size and material properties across different regions of the manufactured component.
Innovation Solution
The method involves determining an energy application parameter based on the intersection area relationship between a virtual geometric shape and the previously formed portion of the component, supplying feedstock material, and delivering energy to form a melt pool, with the amount of energy adjusted to ensure uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed amount of energy is applied during additive manufacturing, then the process is simple to control, but non-uniformities are produced in the manufactured component
Solution Approach 1:
The patent applies local quality by determining location-specific energy application parameters based on the geometric shape at each addition location. The controller adjusts the amount of energy delivered according to the local intersection area between the virtual geometric shape and the previously formed portion, ensuring each region receives appropriate energy for uniform consolidation without over-simplifying to a fixed energy approach.
Solution Approach 2:
The patent implements dynamics by making the energy application parameter variable rather than fixed. The controller dynamically adjusts the energy amount based on real-time determination of the virtual geometric shape's intersection area with the previously formed portion, allowing the system to adapt to changing geometric conditions during the additive manufacturing process.
2Strength
If too much energy is applied in some areas, then consolidation is improved, but non-uniformities and defects are produced
Solution Approach 1:
The patent applies feedback by using the determined energy application parameter (based on virtual geometric shape intersection area) to control the energy delivery. This closed-loop approach ensures that each location receives the precise energy amount needed for proper consolidation, preventing both over-energy and under-energy conditions that would cause non-uniformities.
Solution Approach 2:
The patent implements parameter changes by varying the energy application parameter according to the local geometry. The controller modifies the energy amount based on the intersection area calculation, ensuring optimal consolidation at each location without applying excessive energy that would create defects or non-uniformities.
3Loss of energy
If too little energy is applied in other areas, then energy waste is reduced, but non-uniformities and defects are produced
Solution Approach 1:
The patent applies local quality by calculating the specific energy requirement for each addition location based on the virtual geometric shape's intersection area with the previously formed portion. This ensures that each area receives exactly the energy it needs for proper consolidation, avoiding both energy waste from over-application and defects from under-application.
Solution Approach 2:
The patent uses feedback control where the determined energy application parameter guides the energy delivery system. This ensures that sufficient energy is applied to achieve uniform consolidation at each location while avoiding unnecessary energy waste, as the energy amount is precisely matched to the local geometric requirements.
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 allows for better control of melt pool size and material properties, reducing defects and ensuring consistent quality across 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 intersection area relationship that describes an area of intersection between the previously formed portion and a surface of a virtual geometric shape, which is positioned at the addition location, as a function of a size parameter of the virtual geometric shape. The methods also include supplying a feedstock material to the addition location. The methods further include delivering 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.