Interferometer-Guided Laser Metal Deposition Geometry Control
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Solution Overview
Problem
Laser metal deposition (LMD) requires precise adjustment of process parameters for effective manufacturing, but existing methods for monitoring the geometry and quality of the deposited material are limited, providing only conditional statements about the absolute geometry of the component, which hampers process control and manufacturing precision.
Innovation Solution
An apparatus and method utilizing an interferometer unit to measure the topography and distance of the workpiece surface during LMD, enabling precise control of process parameters through closed-loop or open-loop control systems, allowing for accurate determination of the component's geometry and adaptation of process variables in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If camera-based methods or pyrometer-based methods are used for melt pool geometry analysis or temperature measurement, then process monitoring is enabled, but absolute geometry information cannot be provided or can only be provided conditionally
Solution Approach 1:
The patent replaces mechanical/contact-based measurement methods with optical measurement methods. Specifically, it uses optical projection and imaging systems to non-contactly measure the three-dimensional geometry of deposited material, enabling absolute geometry information to be obtained without physical interference with the melt pool or deposited material.
Solution Approach 2:
The patent introduces an optical intermediary system consisting of a projection device and imaging device. The projection device projects structured light patterns onto the workpiece surface, and the imaging device captures the deformed patterns, which are then processed to reconstruct three-dimensional geometry. This intermediary optical system enables indirect but accurate measurement of absolute geometry.
2Manufacturing precision
If laser metal deposition is performed with precise adjustment of process parameters, then manufacturing quality is improved, but the process is sensitive to parameter deviations and requires continuous monitoring
Solution Approach 1:
The patent implements a feedback control system where the three-dimensional geometry of deposited material is measured in real-time during the laser metal deposition process. The measured geometry information is fed back to the control system, which automatically adjusts process parameters (such as laser power, deposition speed, or material feed rate) to maintain manufacturing precision and compensate for deviations.
Solution Approach 2:
The patent performs preliminary measurement of the workpiece surface geometry before deposition begins and during intermediate stages. This preliminary information is used to pre-adjust process parameters or deposition paths to anticipate and prevent geometry deviations, rather than merely reacting to deviations after they occur.
3Productivity
If secondary emissions from the interaction process are used for measurement, then process monitoring is enabled, but absolute geometry statements cannot be provided
Solution Approach 1:
The patent introduces an optical intermediary system consisting of a projection device and imaging device. The projection device projects structured light patterns onto the workpiece surface, and the imaging device captures the deformed patterns, which are then processed to reconstruct three-dimensional geometry. This intermediary optical system enables indirect but accurate measurement of absolute geometry.
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 enhances manufacturing precision and fidelity, enabling the reliable production of complex three-dimensional components by continuously monitoring and adjusting process parameters, thus improving the overall quality and consistency of the additive manufacturing process.
Implementation Method 1
an interferometer unit configured to measure, by means of at least one optical measurement beam, a surface of the workpiece
Data Source
AI summary
The invention relates to a device (100) for an additive manufacture. The device (100) comprises a laser device (110) for machining material using a laser beam (112), said laser device (110) being designed to deflect the laser beam (112) onto a machining region of a workpiece (10); at least one supply device (130) for a supply material, said supply device being designed to supply the supply material to the machining region; and an interferometer (140) which is designed to measure a distance to the workpiece (10) by means of an optical measuring beam (142).