Dual Beam Additive Manufacturing Cooling Control
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Solution Overview
Problem
Existing additively manufactured three-dimensional objects face challenges in achieving reliable control over the cooling behavior of selectively consolidated layers, which affects their structural properties and microstructure, leading to potential internal stress and crack formation.
Innovation Solution
An apparatus that generates two energy beams with different properties, where a first beam fuses the build material and a second beam tempers it, allowing for controlled cooling behavior by detecting and evaluating the radiation emitted from the selectively irradiated layers to adjust the energy input and achieve desired microstructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single energy beam is used to irradiate and consolidate layers of powdered build material, then the manufacturing process is simple, but the cooling behavior and microstructure of the consolidated portions cannot be reliably controlled
Solution Approach 1:
The single energy beam is segmented into multiple beams with different properties. The first energy beam is optimized for fusing/build material consolidation, while the second energy beam is optimized for tempering/cooling control. This segmentation allows independent optimization of each beam's parameters to achieve precise control over cooling behavior and microstructure.
Solution Approach 2:
Different regions of the build material receive different quality energy beams at different locations. The first beam provides high energy density for fusion at the consolidation zone, while the second beam provides controlled energy for tempering at the cooling zone. This local differentiation enables precise control of cooling behavior without compromising the overall manufacturing process.
2Productivity
If the cooling behavior of consolidated layers is not controlled, then the manufacturing process is fast, but internal stresses and cracks form compromising structural properties
Solution Approach 1:
The second energy beam is positioned to follow the first beam's path with a defined offset, preparing the material in advance for controlled cooling. The tempering beam is ready to activate immediately after the fusion beam completes its scan, ensuring that cooling control is established before the layer is fully consolidated, preventing stress and crack formation.
Solution Approach 2:
The system employs detection devices to monitor the cooling behavior of consolidated portions in real-time. The evaluation device processes this feedback information and adjusts the second energy beam's parameters dynamically to maintain optimal cooling rates, ensuring structural integrity while preserving manufacturing speed.
3Manufacturing precision
If multiple energy beams are used to control cooling behavior, then the microstructure and structural properties are improved, but the device complexity increases
Solution Approach 1:
Multiple energy beams are merged into a single integrated irradiation device that coordinates their operation. The control device synchronizes the first and second beams, managing their sequential activation and spatial positioning. This merging approach enables precise microstructure control while avoiding the complexity of completely separate beam systems.
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 reliable and integratable determination of cooling behavior, enhancing the structural properties of additively manufactured objects by controlling temperature and microstructure through real-time feedback loops.
Implementation Method 1
an irradiation device configured to selectively irradiate a layer of build material with at least a first and a second energy beam
Implementation Method 2
The first energy beam may have a beam power high enough to fuse, i.e. particularly melt, build material while being selectively irradiated with the first energy beam
Implementation Method 3
The second energy beam may have a beam power not high enough to fuse, i.e. particularly melt, build material while being selectively irradiated with the second energy beam. The energy input into selectively irradiated portions of a layer of build material by the second energy beam is yet, sufficient for tempering portions of a layer of build material after being selectively irradiated with the first energy beam
Implementation Method 4
a detection device configured to detect (electromagnetic) radiation emitted or reflected from a portion of a layer of build material which was selectively irradiated by the first energy beam
Data Source
Figure 1
AI summary
Apparatus (1) for additively manufacturing three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers (2) of a powdered build material (3) which can be consolidated by means of an energy beam (4), the apparatus (1) comprising: - an irradiation device (8) configured to generate at least a first and a second energy beam (4, 9), whereby the second energy (9) beam follows the path of the first energy beam (4) with a defined local and/or time offset; - a detection device (11) configured to detect radiation (12) emitted from a portion of a layer (2) of powdered build material (3) which was selectively irradiated by the first energy beam (4), - an evaluation device (14) configured to evaluate detected radiation (12) emitted from a portion of a layer (2) of powdered build (3) material which was selectively irradiated by the first energy beam (4) with regard to the cooling behavior of the portion of the layer (2) of powdered build material (3) which was selectively irradiated by the first energy beam (4).