Additive Manufacturing Residual Stress Closed-Loop Control
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Solution Overview
Problem
Additive manufacturing processes face challenges with residual stresses that cause deformation and distortion in components, particularly in larger and thicker welds or multiple layers, leading to potential cracks and geometry changes, which are critical in aerospace components.
Innovation Solution
An additive manufacturing system with thermal sensors and a computing device to measure and predict residual stresses in-situ, adjusting the build strategy by controlling energy and powder delivery to manage or leverage residual stresses, ensuring final dimensions match planned dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to form three-dimensional structures layer-by-layer, then complex geometries and rapid prototyping are enabled, but residual stresses cause deformation and distortion in the component
Solution Approach 1:
The system performs preliminary measurements of residual stresses during the additive manufacturing process using thermal sensors. The computing device calculates residual stresses based on temperature data from multiple sensors positioned at different locations on the component, enabling prediction of final dimensions before completion of manufacturing.
Solution Approach 2:
The system implements closed-loop control by continuously monitoring residual stresses during manufacturing and using this feedback to adjust the build strategy. The computing device compares predicted final dimensions with planned dimensions and modifies energy delivery or powder delivery parameters to counteract residual stress effects and maintain dimensional accuracy.
2Manufacturing precision
If thermal sensors are added to measure temperature and determine residual stress, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The thermal sensors serve multiple functions: they measure temperature at different locations on the component, provide data for residual stress calculation, and enable real-time monitoring of thermal history. This multi-functionality reduces the need for separate measurement systems while maintaining high manufacturing precision.
Solution Approach 2:
The system replaces complex mechanical stress measurement methods with thermal-based measurement. By using thermal sensors to measure temperature and calculating residual stresses from thermal data, the system avoids the complexity of mechanical strain gauges or destructive testing methods while achieving the same measurement objective.
3Manufacturing precision
If residual stress management is implemented through closed loop control, then manufacturing precision is improved, but productivity may be reduced due to additional monitoring and control steps
Solution Approach 1:
The residual stress management system operates continuously during the additive manufacturing process without interrupting production. Thermal sensors continuously monitor temperature, the computing device continuously calculates residual stresses and predicts final dimensions, and control adjustments are made in real-time, maintaining continuous manufacturing flow while ensuring precision.
Solution Approach 2:
The system uses the thermal data naturally generated during the manufacturing process itself to monitor and control residual stresses. By utilizing the existing thermal field and energy delivery mechanisms, the system avoids adding separate monitoring infrastructure that would slow down production, enabling self-monitoring without productivity loss.
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
Reduces energy, material waste, and labor by preventing deformation and ensuring accurate component dimensions through closed-loop control of residual stresses, allowing for precise manufacturing.
Implementation Method 1
an energy delivery device configured to deliver energy to a build surface of an additively-manufactured component to form a melt pool in the build surface of the component
Implementation Method 2
may melt or sinter the powdered material together in predetermined shapes to form the three-dimensional structures
Implementation Method 3
one or more thermal sensors configured to measure a temperature of a first portion of the additively-manufactured component and a second portion of the additively manufactured component
Implementation Method 4
Residual stresses, such as those caused by different portions of the component thermally expanding and/or contracting at different rates, may cause deformation of the component
Data Source
AI summary
An additive manufacturing system includes an energy delivery device configured to deliver, a powder delivery device, and one or more thermal sensors configured to measure a temperature of a first portion of the additively-manufactured component and a second portion of the additively manufactured component. The additive manufacturing system includes a computing device configured to receive data indicative of the temperature of the first portion and of the second portion, determine a residual stress of the additively-manufactured component based at least partially on the received thermal sensor data from the first portion of the additively-manufactured component and the received data from the second portion of the additively-manufactured component; and predict final dimensions of the additively-manufactured component based at least partially on the determined residual stress of the additively-manufactured component.