Additive Manufacturing Process With In-Situ Stress and Layer Control
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Solution Overview
Problem
Laser-based additive manufacturing faces challenges with low energy efficiency and slow deposition rates, limiting its applications and ability to build large parts due to small chamber sizes and high accuracy at the expense of speed.
Innovation Solution
A method involving powder characterization, in-situ inspection using flash thermography and ultrasonic measurement to control layer characteristics and residual stress, allowing for closed-loop process adjustments, including laser processing and cleanup, to achieve higher deposition rates and larger volumes with precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If small bead size with small layer buildup (20-100 μm thickness per pass) is used to achieve high accuracy, then manufacturing precision is improved, but deposition rate deteriorates to very slow speeds
Solution Approach 1:
The patent changes the layer thickness parameter from the conventional 20-100 μm range to a much thicker range, enabling rapid deposition while maintaining acceptable precision through process optimization and in-situ monitoring systems
Solution Approach 2:
The patent implements in-situ inspection systems that provide real-time feedback on layer quality, allowing the process to maintain precision even with thicker layers and faster deposition rates by detecting and correcting deviations during the manufacturing process
2Manufacturing precision
If conventional laser based material deposition is used to achieve precise coating deposition, then manufacturing precision is improved, but energy efficiency deteriorates to low levels
Solution Approach 1:
The patent optimizes laser processing parameters including power, speed, and focal position to improve energy efficiency while maintaining coating precision, allowing for more efficient material deposition with reduced energy consumption
3Manufacturing precision
If small chamber sizes are used in laser based material deposition, then manufacturing precision is maintained, but the ability to build large parts deteriorates
Solution Approach 1:
The patent employs multiple laser sources and/or multi-axis positioning systems that enable precise control over large volumes by dividing the processing space into manageable zones, maintaining manufacturing precision while expanding part size capability
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 enables faster and more efficient additive manufacturing by increasing layer thickness and deposition rates, reducing production time from 30-40 hours to approximately 4 hours, while maintaining precision and preventing defects and warping through real-time control of residual stress.
Implementation Method 1
laser processing the powder materials
Implementation Method 2
laser processing the powder materials
Implementation Method 3
inspecting via ultrasonic measurement process the laser processed powder materials to determine residual stress
Implementation Method 4
inspecting, in-situ, the powder materials deposited to determine layer characteristics
Data Source
AI summary
A method of additive manufacturing a component. The method includes selecting powder characterization, depositing powder materials, inspecting the powder materials, selecting process and laser parameters for laser processing, laser processing the powder materials, performing layer cleanup, determining stress state and relieving, additionally inspecting the laser processed powder materials, and repeating steps until a buildup of the component is complete.