Additive Layer Resonance Checking for In-Process Defect Detection
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Solution Overview
Problem
Existing additive production methods, such as selective laser melting (SLM), struggle to achieve material quality comparable to casting methods, particularly in turbine components, due to structural defects and thermal tensions, which are only detectable after completion, leading to inefficient production and potential device damage.
Innovation Solution
A method for in-situ material testing during additive production, involving mechanical excitation of layers and measurement of mechanical response signals to detect structural defects and deviations from predetermined tolerance ranges, allowing for real-time warning and termination of the production process to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive production methods (SLM, SLS, EBM) are used to produce turbine components, then production flexibility and complexity handling are improved, but material quality and structural integrity deteriorate due to structural defects and thermal tensions
Solution Approach 1:
The patent applies preliminary action by performing mechanical excitation and testing of individual layers during the additive production process itself, before the entire component is complete. This allows defects to be detected early while the component is still being built, enabling immediate corrective actions rather than waiting until after production is finished.
Solution Approach 2:
The patent implements feedback by continuously monitoring mechanical response signals from each produced layer and comparing them against expected values. When deviations indicate structural defects or detachment, the system provides feedback to terminate production or alert operators, creating a closed-loop quality control system that actively maintains material quality.
2Measurement precision
If testing is performed after completion of additive production, then comprehensive quality assessment is achieved, but production time and efficiency deteriorate due to inability to detect defects during production
Solution Approach 1:
The patent applies segmentation by dividing the quality testing process into discrete steps corresponding to individual layers or groups of layers. Instead of testing the entire component after completion, the production process is segmented into build phases with intermittent testing phases, allowing continuous monitoring without halting the entire production workflow.
Solution Approach 2:
The patent performs preliminary testing actions during the production process itself rather than after completion. By exciting and measuring each layer as it is produced, the system achieves comprehensive quality assessment while maintaining production continuity, eliminating the need for separate post-production testing phases.
3Productivity
If production continues without real-time defect detection, then production speed is maintained, but device damage risk increases due to undetected structural flaws and detachment
Solution Approach 1:
The patent implements a feedback mechanism where mechanical response signals from each layer are continuously monitored and compared against predetermined tolerance ranges. When defects are detected, the system automatically provides feedback to terminate production or alert operators, preventing continued operation with damaged components that could cause further device damage.
Solution Approach 2:
The patent converts the potentially harmful continuation of production with defective components into a benefit by using the mechanical excitation and testing process to detect defects early. The same vibrations used for testing serve as an early warning system, transforming what could be a source of damage into a protective diagnostic tool.
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
Enables early detection and prevention of structural flaws and detachment, optimizing production efficiency by avoiding the construction of damaged components and protecting equipment, thus ensuring higher material quality and reduced machine runtime.
Implementation Method 1
the mechanical excitation of at least one additively constructed layer of the component during a production of the component
Implementation Method 2
the measurement of a mechanical response signal of the component, constructed up to this point in time
Data Source
AI summary
A method for checking a component to be produced in an additive manner, having the steps of mechanically exciting at least one additively constructed layer of the component during the additive production of the component, measuring a mechanical response signal of the component, and displaying a warning and/or interrupting the additive production of the component if the mechanical response signal lies outside of a specified tolerance range. A device for the additive production of a component, includes a device for mechanically exciting the at least one additively constructed layer of the component, a measuring unit for measuring the mechanical response signal of the component, and a control unit. The control unit is designed to display the warning and/or interrupt the additive production if the mechanical response signal lies outside of a specified tolerance range.