Additive Manufacturing Quality Assessment Using Micro-Tomography
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Solution Overview
Problem
Additive Manufacturing (AM) processes face challenges in detecting small voids and defects within produced objects, as conventional methods are inadequate for verifying the operational integrity and quality of the AM apparatus during the build process, especially due to the complexity of variables involved.
Innovation Solution
A method combining Additive Manufacturing (AM) and micro-tomography processes to create test specimens from the same material as the damaged object, allowing for the production of 3D digital models that assess the internal structure and detect defects, thereby verifying the AM apparatus's operation and material quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional inspection methods are used to detect voids and defects in AM objects, then the inspection process is simple, but the detection precision is insufficient for small voids and defects
Solution Approach 1:
The patent introduces test specimens as intermediary objects that are built alongside the actual AM object. These test specimens serve as mediators to assess the operational integrity of the AM apparatus and the quality of deposited material. By analyzing defects in the test specimens using micro-tomography, the system indirectly evaluates the quality of the main object without requiring direct inspection of the entire object, thus achieving high detection precision while managing inspection complexity.
Solution Approach 2:
The patent creates test specimens that are essentially copies or replicas built using the same AM process and material as the actual object. These test specimens replicate the manufacturing conditions and potential defects. By analyzing the copied specimens rather than the original object itself, the system achieves precise defect detection while simplifying the overall inspection process.
2Reliability
If test specimens are built using the same AM process and material as the damaged object, then the thermal characteristics and microstructure are representative, but the build time and material consumption increase
Solution Approach 1:
The patent applies partial action by building test specimens that contain only the essential features needed for quality assessment, rather than replicating entire large-scale objects. The test specimens are designed to be minimal in size while still capturing the critical thermal characteristics and microstructure of the actual AM process. This allows reliable quality assessment with reduced build time and material consumption.
3Reliability
If multiple test specimens are built at different stages of the AM process, then the operational integrity can be assessed throughout the build process, but the complexity of the assessment process increases
Solution Approach 1:
The patent segments the quality assessment process into distinct stages by building multiple test specimens at different points in the AM build process (e.g., before, during, and after material deposition). Each test specimen corresponds to a specific stage, allowing the system to verify operational integrity at each segment independently. This segmentation makes the complex assessment process more manageable and systematic.
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 effectively detects small voids and defects, ensuring the AM apparatus operates correctly and the added material is acceptable, improving the assessment of material quality and reducing the need for extensive testing of the final object.
Implementation Method 1
performing, using micro-tomography apparatus, on the produced test specimen, a micro-tomography process to create a model (e.g. a 3-dimensional digital model)
Implementation Method 2
using a powerful heat source such as a laser beam, electron beam or an electric, or plasma welding arc, melting an amount of that material and depositing the melted material
Data Source
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AI summary
Methods and apparatus for producing and assessing at least part of an object (2), the methods comprise: performing, using Additive Manufacturing apparatus (8), an Additive Manufacturing process to produce a test specimen (30, 34, 38) and at least part of an object (2); performing, using micro-tomography apparatus (40), on the test specimen (30, 34, 38), a micro-tomography process to create a digital model (50) of the internal structure of the test specimen (30, 34, 38); determining whether or not the model (50) satisfies one or more criteria; and, if the model (50) satisfies the criteria, determining that the at least part of the object (2) produced by performing the Additive Manufacturing process is acceptable,or, if the model (50) does not satisfy the criteria, determining that the at least part of the object (2) produced by performing the Additive Manufacturing process is not acceptable.