Laser Additive Manufacturing Beam Offset Calibration via Fluid-Flow Coupons
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Solution Overview
Problem
Current methods for manufacturing complex parts with specific air flow requirements in gas turbine engines are time-consuming and prone to errors, particularly in determining the beam offset for laser additive manufacturing machines and ensuring repeatability and compliance with specifications.
Innovation Solution
A method involving the use of fluid-flow coupons to calibrate the beam offset of laser additive manufacturing machines, ensuring accurate air flow performance by correlating beam offset with flow parameters and determining target beam offset values for consistent air flow output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If beam offset is determined via measurement of macro scale physical artefacts, then the laser additive manufacturing machine can be calibrated, but the process is time consuming and prone to errors
Solution Approach 1:
The patent uses fluid-flow coupons as simplified copies or proxies for actual engine components. These coupons contain flow features that replicate the critical flow characteristics of full-scale parts but in a reduced, easily measurable form. By measuring flow rates through these coupon models rather than full-scale artifacts, the calibration process achieves the same beam offset determination accuracy while dramatically reducing measurement complexity and time requirements
Solution Approach 2:
The fluid-flow coupons serve as an intermediary medium between the laser additive manufacturing process and the final component validation. Instead of directly measuring beam offset on macro scale physical artifacts or final components, the method uses these intermediate coupon specimens with known flow characteristics to indirectly determine the beam offset value, simplifying the measurement process while maintaining accuracy
2Manufacturing precision
If ad-hoc file manipulation methods are used to meet specifications, then manufacturing compliance can be achieved, but the process is time consuming and difficult to industrialise
Solution Approach 1:
The patent establishes beam offset calibration curves and flow parameter relationships before actual component manufacturing begins. By pre-determining the relationships between beam offset values and resulting flow characteristics through coupon testing, the method eliminates the need for time-consuming ad-hoc file manipulations during production. Operators can directly select appropriate beam offset values from pre-established calibration data, ensuring specification compliance while dramatically improving manufacturing efficiency and enabling industrialization
Solution Approach 2:
The method transforms the manufacturing approach by changing from ad-hoc file manipulation to a parameter-based system. Instead of manually adjusting design files for each part to meet specifications, the patent establishes systematic relationships between beam offset parameters and flow outcomes. This allows direct selection of optimal parameters from calibration curves, ensuring specification compliance through controlled parameter selection rather than iterative file adjustments, thereby improving productivity
3Adaptability or versatility
If different machine conditions are used during manufacturing, then production flexibility is maintained, but repeatability of manufactured parts decreases
Solution Approach 1:
The patent implements a feedback mechanism where actual flow measurements from fluid-flow coupons are used to verify and adjust beam offset settings. By measuring the actual flow rate through coupons manufactured under specific machine conditions and comparing it against target values from calibration curves, the system provides feedback that allows operators to compensate for variations in machine conditions. This feedback loop ensures that despite differences in machine states, the final component flow characteristics remain consistent and repeatable
Solution Approach 2:
The method replaces reliance on strict mechanical control of machine conditions with a measurement and calculation-based approach. Instead of requiring identical machine conditions for repeatable results, the patent uses flow measurement feedback and calibration curve calculations to determine the actual beam offset achieved. This substitution of mechanical precision requirements with measurement-based verification allows production flexibility while maintaining parts repeatability through computational compensation
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 method provides a cost-effective and time-effective approach to manufacturing complex parts with improved repeatability and air flow compliance, ensuring that components meet desired specifications and maintain performance consistency across different machines and components.
Implementation Method 1
laser additive manufacturing machine
Implementation Method 2
melted by the laser beam 316 onto the powder material
Implementation Method 3
measuring a fluid flow rate of the fluid flow through the at least one first fluid-flow coupon
Data Source
AI summary
A method of operating a laser additive manufacturing machine includes manufacturing at least one first fluid-flow coupon, that includes a plate defining a plurality of holes, at a corresponding beam offset value of the laser additive manufacturing machine. The method further includes disposing the at least one first fluid-flow coupon in a testing rig, directing a fluid flow towards the at least one first fluid-flow coupon, measuring a fluid flow rate through the at least one first fluid-flow coupon, determining a calibration curve by correlating a beam offset of the laser additive manufacturing machine with a flow parameter based on the fluid flow rate through the at least one first fluid-flow coupon and the corresponding beam offset value, determining a target beam offset value corresponding to a target flow value of the flow parameter, and calibrating and operating the laser additive manufacturing machine using the target beam offset value.