Irradiation Control Device for Additive Manufacturing Quality
Solution Overview
Problem
Existing methods for determining component quality in three-dimensional object production by selective solidification fail to accurately account for different exposure types, leading to incorrect classification of component properties and quality due to varying melt pool signals.
Innovation Solution
An irradiation control device and method that outputs control commands and irradiation types in real-time, allowing for precise correlation of melt pool signals with the type of exposure, thereby enabling accurate evaluation of component quality and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If different exposure types are used to solidify different partial areas of the object cross-section, then the melted areas can have different properties, but this leads to varying melt pool signals that cause incorrect classification of component properties and quality
Solution Approach 1:
The system performs preliminary classification of areas to be solidified into different partial model areas (contour area, interior area, downward-facing surfaces) before the actual solidification process. Each area is pre-assigned a specific exposure type based on its geometric characteristics and required properties. This preliminary classification enables the evaluation unit to correctly interpret melt pool signals by knowing in advance which exposure type is being applied, thus preventing incorrect quality assessment.
Solution Approach 2:
The system changes exposure parameters (radiation energy density, scanning pattern, exposure type) based on the specific partial model area being processed. The control unit adjusts these parameters dynamically during the layer-by-layer construction process. By correlating these parameter changes with the evaluation unit, the system can accurately interpret melt pool signals despite the varying exposure conditions, thereby maintaining component quality evaluation accuracy.
2Device complexity
If the irradiation type is not taken into account when evaluating the melt pool signal, then the evaluation process is simpler, but this leads to incorrect classification of component properties and quality
Solution Approach 1:
The system implements a feedback mechanism where the evaluation unit receives both the melt pool signal and information about the current exposure type from the control unit. This feedback loop enables the evaluation unit to adjust its interpretation of the melt pool signal based on the specific exposure conditions. The system continuously monitors and correlates exposure parameters with melt pool characteristics, ensuring accurate quality assessment without requiring overly complex additional hardware.
3Measurement precision
If real-time output of irradiation type is implemented, then correct evaluation of component quality is enabled, but this requires precise timing coordination between control commands and irradiation type data
Solution Approach 1:
The control unit continuously outputs irradiation type information in real-time throughout the solidification process, ensuring that the evaluation unit always has current data for accurate melt pool signal interpretation. This continuous data flow eliminates gaps or delays in information availability, maintaining precise correlation between exposure parameters and quality measurements without significant time offsets.
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
Ensures correct evaluation of component quality by minimizing time offsets between control commands and irradiation types, allowing for precise association of melt pool signals with exposure types, thus improving the accuracy of component property assessment.
Implementation Method 1
selectively scanning the layer with electromagnetic radiation or particle radiation
Implementation Method 2
an irradiation device which emits electromagnetic radiation or particle radiation and is able to irradiate areas to be solidified
Implementation Method 3
the building material in each layer is selectively solidified by selectively irradiating locations corresponding to a cross section of the object to be produced with a laser beam. In the process, the powder grains are partially or completely melted at these points by the energy introduced by the radiation, so that after cooling they are connected to one another as solid bodies
Implementation Method 4
The molten pool created by the energy input can be detected by a detector
Data Source
Figure 1
Figure 2
AI summary
An irradiation control device (31) serves to equip and/or retrofit an additive manufacturing device (1). The latter has an irradiation device (20) that emits electromagnetic radiation (22) or particle radiation and is capable of irradiating areas to be solidified in a layer such that, after cooling, they exist as an object cross-section or part thereof. The irradiation control device (31) has a first data output interface (36) at which control commands can be issued to the irradiation device (20). The issued control commands specify one of a plurality of irradiation types, wherein an irradiation type is defined by a predefined combination of a radiation energy density to be emitted by the irradiation device (20) and a scanning pattern with which the radiation (22) is directed onto a region of a layer of the build-up material (15).Furthermore, the irradiation control device (31) has a second data output interface (37) at which an irradiation type can be output in real time in relation to a temporal sequence of the output of a control command specifying this irradiation type.