Additive Manufacturing Test Article for Defect Source Identification
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Solution Overview
Problem
In additive manufacturing, it is challenging to discern whether defects in components are due to design flaws or equipment issues, making it difficult to assess build quality and identify underlying problems.
Innovation Solution
A test article is created using additive manufacturing techniques with specific geometric features such as angled flat surfaces and curved surfaces, which can be compared to the actual component to evaluate build quality and detect defects without damaging the component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing is used to produce components with complex geometries, then manufacturing efficiency and material utilization are improved, but it becomes difficult to discern whether defects are caused by design flaws or equipment issues
Solution Approach 1:
The patent introduces a test article as an intermediary object between the additive manufacturing system and the quality assessment process. This test article contains known geometric features and defects that serve as a reference standard, allowing operators to distinguish between defects caused by equipment issues versus design flaws by comparing actual components against the test article outcomes
Solution Approach 2:
The test article creates a copy or replica of expected geometric features with known characteristics. By manufacturing this test article alongside actual components using the same additive manufacturing system, operators can compare the two to identify whether deviations in actual components stem from equipment problems or design issues
2Adaptability or versatility
If conventional manufacturing methods are used to machine components from solid billets, then design flexibility is improved, but material waste increases significantly
Solution Approach 1:
The patent transitions from subtractive manufacturing parameters (machining, cutting) to additive manufacturing parameters (layer-by-layer deposition, selective melting). This fundamental parameter change enables the creation of complex geometries that would be impossible or extremely wasteful to produce through conventional machining, as material is added only where needed rather than removing large portions from solid billets
3Measurement precision
If visual inspection is used to detect defects in additively manufactured components, then detection capability is improved, but inspection time and complexity increase for complex shapes
Solution Approach 1:
The test article is manufactured concurrently with actual components during the same additive manufacturing build process. This preliminary action allows quality assessment to be performed on the test article first, establishing baseline expectations before inspecting actual components, thereby reducing the time and complexity of subsequent inspections
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 method allows for the detection of similar defects in concurrently manufactured components without visual inspection, particularly useful for complex shapes, and helps assess the calibration and material quality of the additive manufacturing system.
Implementation Method 1
The melting may be performed by a high power melting beam, such as a 100 Watt ytterbium laser, to fully weld (melt) the metal powder to form a solid metal
Implementation Method 2
a second surface including a plurality of angled flat surface portions, each of the plurality of angled flat surface portions having a distinct angle with respect to the horizontal plane
Data Source
AI summary
Embodiments of the disclosure provide a test article for additive manufacture and related methods. A test article formed may include a body having a forward face and a rearward face horizontally opposite the forward face. A first surface extending between the forward face and the rearward face of the body may include a plurality of protrusions for removable coupling of the body to a build plate. A second surface on the body may extend between the forward face and the rearward face of the body, and may include a plurality of angled flat surface portions. Each of the plurality of angled flat surface portions may have a distinct angle with respect to a horizontal plane of the body. An angular difference between each adjacent angled flat surface portion in the plurality of angled flat surface portions is substantially uniform.