Magnetic Incremental Permeability for 3D Printed Yield Strength
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Solution Overview
Problem
Existing 3D printing technologies lack a non-destructive and real-time method to determine the yield strength of metallic members, leading to wasted production efforts and increased costs due to destructive testing.
Innovation Solution
A method and system using magnetic incremental permeability (MIP) and the Hall-Petch relationship to non-destructively measure the grain size and yield strength of metallic members during 3D printing, employing an electromagnet, Hall sensor, transmitting coil, and sensing coil to calculate yield strength without damaging the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If destructive tensile test is performed on 3D printed parts after manufacturing, then yield strength can be determined, but production effort is wasted and costs increase due to destruction of parts
Solution Approach 1:
The patent replaces the mechanical destructive tensile test with a magnetic field-based non-destructive measurement system. The system uses an electromagnet to generate a magnetic field that penetrates the 3D printed part, and a Hall sensor to detect magnetic flux changes, thereby determining yield strength without physically destroying the part.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary medium to indirectly measure the mechanical property (yield strength) of the 3D printed part. The magnetic field interacts with the part's microstructure through magnetic permeability, allowing yield strength determination without direct mechanical stress application that would cause destruction.
2Measurement precision
If destructive tensile test is performed on 3D printed parts, then yield strength can be measured, but measurement cost increases as the number of test objects increases
Solution Approach 1:
The patent replaces expensive destructive mechanical testing with a non-destructive magnetic measurement system that uses electromagnetic fields and Hall sensors, significantly reducing the cost per measurement and eliminating the need to destroy test specimens.
Solution Approach 2:
The magnetic measurement system allows the 3D printed part to serve as both the object being manufactured and the object being tested simultaneously, eliminating the need for separate destructive test specimens and reducing overall measurement costs.
3Productivity
If production continues despite initial defects, then more parts can be manufactured, but extra costs are incurred for unnecessary production process
Solution Approach 1:
The patent implements real-time yield strength measurement during the 3D printing process itself, allowing defects to be detected and identified immediately as they occur. This enables early intervention to stop production at the exact moment a defect is detected, preventing wasteful continuation of the manufacturing process.
Solution Approach 2:
The system provides real-time feedback on yield strength during 3D printing by continuously monitoring magnetic permeability changes. This feedback loop allows the production process to be adjusted or stopped immediately when defects are detected, optimizing the balance between production volume and cost efficiency.
4Productivity
If real-time monitoring during 3D printing is implemented, then production efficiency improves, but device complexity increases
Solution Approach 1:
The patent integrates the yield strength measurement function into the existing 3D printing process infrastructure, using the same electromagnetic field generation and sensing components already present in the printing system. This multi-functional approach enables real-time monitoring without adding separate complex dedicated testing equipment.
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 real-time, non-destructive measurement of yield strength, reducing production losses by allowing immediate identification and correction of defects, thereby improving the durability and reducing defect rates of 3D printed metallic products.
Implementation Method 1
measuring an intensity of the quasi-static excitation magnetic field applied to interior of the metallic member using a Hall sensor
Implementation Method 2
applying a quasi-static excitation magnetic field generated by using an electromagnet to enter and exit through two points of a metallic member to be measured
Implementation Method 3
applying an alternating magnetic field (ΔH) smaller than the quasi-static excitation magnetic field generated by a transmitting coil to the metallic member to overlap with the quasi-static excitation magnetic field
Implementation Method 4
detecting, using a sensing coil, a magnetic field induced by the metallic member magnetized by the quasi-static excitation magnetic field and the alternating magnetic field (ΔH)
Data Source
AI summary
For non-destructively measuring the yield strength of a metallic member using magnetic incremental permeability, a quasi-static excitation magnetic field is applied to two points of the metallic member, while a small alternating magnetic field generated by a transmitting coil is applied to the metal member. Intensity of the quasi-static excitation magnetic field applied to the metallic member is measured using a Hall sensor. The magnetic field induced by the magnetized metallic member is detected using a sensing coil. Using signals from the Hall sensor and the sensing coil, a reversible permeability (MIP) of the metallic member is obtained. A grain size of the metallic member is obtained from the relationship between the reversible permeability and the grain size of the metallic member, and the yield strength of the metallic member is calculated using the grain size. The grain size and yield strength of the metallic member can be measured non-destructively.