Build-Plane Induction Coil Inspection for AM Internal Flaw Detection
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Solution Overview
Problem
Current additive manufacturing (AM) methods lack effective in-situ monitoring techniques to detect internal flaws during the build process, leading to wasted time and material due to the inability to identify and classify internal defects before the final structure is completed.
Innovation Solution
A non-destructive inspection system using a build plane induction coil sensor with coplanar magnetization and sensor coils, coupled with a central processing system for complex impedance plane analysis, allows for real-time monitoring and identification of anomalies in the AM build part by comparing impedance data with expected values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If thermal imaging and visual monitoring are used for in-situ inspection, then the most recently formed surface layers can be inspected, but internal flaws below the surface cannot be identified
Solution Approach 1:
The patent replaces thermal imaging and visual monitoring systems with electromagnetic induction-based inspection systems. The induction coils generate electromagnetic fields that penetrate the conductive build material, enabling detection of internal flaws through impedance measurements without relying on surface-level optical or thermal signals.
Solution Approach 2:
The patent introduces electromagnetic fields as an intermediary medium to detect internal flaws. The induction coils generate electromagnetic fields that interact with the conductive build material, and the resulting impedance changes serve as indirect indicators of internal defects, allowing detection without direct visual or thermal contact.
2Measurement precision
If inspection is performed after virtual completion of the final structure, then internal flaws can be identified, but a great deal of time and material is wasted due to early flaws going undetected
Solution Approach 1:
The patent implements preliminary inspection actions during the additive manufacturing build process itself. The induction coils are positioned to inspect layers as they are being formed, allowing early detection of internal flaws before the build is complete, thereby preventing waste of time and material on defective builds.
Solution Approach 2:
The patent establishes a feedback mechanism where impedance measurement results are analyzed in real-time during the build process. When anomalies are detected, the system can provide feedback to stop or adjust the manufacturing process, preventing further investment of time and material in a defective build.
3Quantity of substance
If careful inspection and control of additive material is used, then material quality can be monitored, but accurate identification and classification of internal flaws during the build process is not achieved
Solution Approach 1:
The patent replaces manual or simple sieving inspection methods with electromagnetic induction-based measurement systems. The induction coils measure electrical impedance of the conductive build material, providing precise quantitative data about internal flaws such as voids, inclusions, and density variations that cannot be detected by simple material handling controls.
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
Enables accurate in-situ detection and classification of internal flaws, enabling real-time process adjustments and reducing material waste by providing a closed-loop control mechanism for the additive manufacturing process.
Implementation Method 1
The magnetization coil is configured to induce currents within the build part
Implementation Method 2
the sensor coil is configured to capture impedance data from the build part
Data Source
AI summary
An inspection system for in situ evaluation of an additive manufacturing (AM) build part is provided. The inspection system comprises a build plane induction coil sensor configured and positionable so that during construction of the build part, the sensor's magnetization and sensor coils surround at least the last-produced layer of the AM build part in the build plane. The inspection system further comprises an energization circuit and a central processing system. The central processing system comprises a communication processor configured for sending command signals to the energization circuit and receiving impedance data from the build plane induction coil sensor, and energization controller configured for determining energization commands for transmission to the energization circuit, and an induction data analyzer configured for processing build part impedance data using complex impedance plane analysis and for identifying anomalies in the AM build part.