Additive Manufacturing Controller for Electron Beam Melting
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Solution Overview
Problem
Current additive manufacturing machinery faces challenges in producing high-quality parts due to improper heating and cooling of materials during the electron beam melting process, leading to defects like surface porosity and microcracks, particularly in metals with varying thermal conductivity.
Innovation Solution
A computing device is used to control the electron beam generator by varying the power and speed of the electron beam along different path lines based on the length of the line and the thermal conductivity of the material, ensuring optimal heating and cooling through non-linear power and speed adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the electron beam follows a serpentine pattern with spaced-apart parallel lines to melt and fuse raw material, then the manufacturing process can be completed, but the material cools too much between adjacent path lines causing defects like surface porosity and microcracks
Solution Approach 1:
The patent applies dynamics by making the electron beam power variable rather than constant. The controller adjusts the power level dynamically based on the specific path line being scanned, allowing higher power for lines that require more heat to prevent excessive cooling. This dynamic adjustment resolves the contradiction by maintaining adequate temperature throughout the manufacturing process while completing all necessary melting and fusing operations.
Solution Approach 2:
The patent implements local quality by applying different power levels to different path lines based on their specific requirements. Rather than using a uniform power setting, the system tailors the energy input to each individual line, ensuring that areas prone to excessive cooling receive additional thermal energy. This localized approach prevents defects in specific regions while maintaining overall manufacturing efficiency.
2Device complexity
If the electron beam travels at constant speed along all path lines, then the control process is simple, but areas with longer path lines experience longer cooling times before the beam returns causing quality defects
Solution Approach 1:
The patent applies dynamics by making the electron beam speed variable rather than constant. The controller adjusts the scanning speed dynamically based on the length and characteristics of each path line. For longer path lines where material has more time to cool, the system reduces the scanning speed to minimize the interval between heating cycles. This dynamic speed adjustment maintains optimal temperature control throughout the manufacturing process while managing the increased control complexity.
Solution Approach 2:
The patent implements parameter changes by varying the electron beam scanning speed as a controllable parameter. The system modifies this parameter based on the specific requirements of each path line, particularly the line length and thermal characteristics of the material. By changing the speed parameter adaptively, the system optimizes temperature control without requiring fundamental changes to the manufacturing process architecture.
3Use of energy by stationary object
If the electron beam uses fixed power levels, then the energy consumption is predictable, but metals with higher thermal conductivity cool more rapidly causing quality issues
Solution Approach 1:
The patent implements parameter changes by making the electron beam power a variable parameter rather than a fixed value. The controller adjusts the power level based on the thermal conductivity of the material being processed and the specific requirements of each path line. For materials with higher thermal conductivity that cool more rapidly, the system increases the power input to compensate for the faster heat loss. This adaptive parameter adjustment ensures consistent quality across different metal types while maintaining reasonable energy consumption predictability through systematic control.
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 helps in minimizing defects such as microcracks and porosity by maintaining optimal material temperature, resulting in higher quality parts across various metals.
Implementation Method 1
The electron beam generator may be positioned above the raw material bed and may generate an electron beam onto the raw material in the bed. The electron beam possesses sufficient power to melt particles of the raw material and fuse them together.
Implementation Method 2
The electron beam possesses sufficient power to melt particles of the raw material and fuse them together
Implementation Method 3
The heating and cooling behavior of the raw material may result from the intrinsic thermal conductivity properties of the metals and alloys used.
Data Source
AI summary
A computing device for controlling the operation of an additive manufacturing machine comprises a memory element and a processing element. The memory element is configured to store a three-dimensional model of a part to be manufactured, wherein the three-dimensional model defines a plurality of cross sections of the part. The processing element is in communication with the memory element. The processing element is configured to receive the three-dimensional model, determine a plurality of paths, each path including a plurality of parallel lines, determine a radiation beam power for each line, such that the radiation beam power varies non-linearly according to a length of the line, and determine a radiation beam scan speed for each line, such that the radiation beam scan speed is a function of a temperature of a material used to manufacture the part, the length of the line, and the radiation beam power for the line.