Additive Manufacturing Energy Control for Uniform Melt Pools
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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 within the manufactured component.
Innovation Solution
Determine an energy application parameter based on factors such as thermal dissipation, angle of incidence, material properties, and environmental factors to regulate energy delivery and melt pool formation, using a controller to control the additive manufacturing system.
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
Solution Approach 1:
The patent applies local quality by determining location-specific energy application parameters based on the geometric shape and position within the manufactured component. Different locations receive different energy amounts to compensate for varying thermal dissipation characteristics, ensuring uniform melt pool properties throughout the component while maintaining controlled complexity through automated calculation.
Solution Approach 2:
The patent implements preliminary action by pre-calculating energy application parameters for different locations within the manufactured component before manufacturing begins. The controller stores and retrieves these predetermined parameters based on the addition location, allowing uniform component production without real-time complex adjustments during the manufacturing process.
2Manufacturing precision
If location-specific energy parameters are used to achieve uniform melt pool properties, then manufacturing precision is improved, but the control system complexity increases
Solution Approach 1:
The patent resolves this contradiction by pre-calculating and storing energy application parameters for all possible addition locations within the manufactured component. The controller simply retrieves the appropriate predetermined parameter based on the current addition location, achieving uniform melt pool properties without requiring complex real-time calculations or adjustments during manufacturing.
Solution Approach 2:
The patent uses copying by creating a virtual model of the manufactured component with predetermined energy parameters assigned to different locations. This virtual geometric shape serves as a template that guides the energy application process, allowing the physical manufacturing to follow a pre-planned energy distribution pattern that ensures uniformity.
3Manufacturing precision
If energy application is increased in areas with high thermal dissipation, then uniform material properties are achieved, but total energy consumption increases
Solution Approach 1:
The patent applies local quality by delivering energy based on specific thermal dissipation characteristics at each addition location rather than using a uniform energy approach throughout. This targeted energy application achieves uniform material properties by compensating only where needed, minimizing total energy consumption while maintaining precision.
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 ensures more uniform melt pool size and material properties across the component, reducing defects and improving manufacturing consistency.
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
Implementation Method 2
form a melt pool of the feedstock material at the addition location
Implementation Method 3
consolidating the melt pool with a previously formed portion of the manufactured component to form an additional portion
Implementation Method 4
consolidating the melt pool
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.