Melt Pattern Mapping via Hybrid Infrared Video Imaging
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Solution Overview
Problem
Current methods for inspecting metallic additive manufactured parts are limited, as they primarily focus on external geometry and require time-consuming techniques like X-Ray, UT, or CT scans for internal inspections, which lack resolution or require extensive data collection, making it difficult to achieve high-fidelity dimensional inspections of internal features.
Innovation Solution
A system utilizing an infrared camera and a video camera to record and process images in real-time, generating a hybrid map of the melt pattern during directed energy fabrication, allowing for simultaneous monitoring of internal and external features and enabling real-time corrections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If X-Ray, UT, or CT scans are used to inspect internal features, then internal defects and geometry can be detected, but the inspection process becomes time-consuming and requires days or weeks to obtain 100% coverage
Solution Approach 1:
The patent performs melt pattern mapping during the actual fabrication process itself, capturing images of the melt pool as the laser deposits material. This preliminary action during manufacturing eliminates the need for separate post-build inspection processes, providing internal feature data before the part is complete while avoiding time-consuming CT scans that would take days or weeks.
Solution Approach 2:
The patent creates a digital copy or map of the internal melt pattern using infrared and visible cameras during fabrication. This optical copy of the internal geometry is obtained in real-time during manufacturing, replacing the need for physical CT scanning after production and reducing inspection time from weeks to minutes.
2Measurement precision
If CT inspection is used to provide three-dimensional view of internal component, then internal defects and geometry can be determined, but the process requires a large number of pulses for each thin slice causing inspections to take days or weeks
Solution Approach 1:
The system captures three-dimensional internal geometry information during the fabrication process itself by mapping melt patterns layer by layer as they are created. This preliminary capture of data during manufacturing eliminates the need for slow post-build CT scanning, providing complete internal geometry maps in real-time rather than requiring days of pulsed inspection after production.
Solution Approach 2:
The patent uses continuous optical imaging during the continuous fabrication process to map internal features. Instead of using discrete pulses that require days to scan through multiple thin slices, the system continuously records melt pool information as material is deposited, maintaining productive action throughout the entire inspection process.
3Measurement precision
If contact probe inspection is used to inspect internal dimensions, then limited internal dimensions can be measured, but the inspection is limited to specific locations and lacks comprehensive coverage
Solution Approach 1:
The patent creates a complete digital optical map of internal melt patterns using camera systems that capture images from multiple angles during fabrication. This comprehensive optical copy provides full three-dimensional internal geometry data, unlike contact probes that can only access limited locations, enabling measurement of all internal dimensions without physical contact with the part.
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 dimensional inspection and feedback control, reducing the need for post-build inspections and allowing for accurate mapping of complex internal geometries, thereby improving the fabrication of metallic parts by providing a comprehensive three-dimensional model of the part as it is built.
Implementation Method 1
An infrared camera and a video camera are used to record images of the pattern of melted material
Implementation Method 2
A directed energy fabrication system includes a controllable energy beam source for generating an energy beam along a directed path. A meltable material is provided in the directed path wherein a selected portion of the meltable material melts
Data Source
AI summary
A method and system are provided for mapping a melt pattern of material created during directed energy fabrication. An infrared camera and a video camera are provided to record images of the pattern of melted material. Each frame of the infrared camera's images is processed to generate a first map of pixels identifying pixels indicative of a highest temperature greater than or equal to a liquidus temperature of the meltable material. Each frame of the video camera's images is processed to generate a second map of pixels identifying pixels indicative of a highest temperature greater than or equal to the liquidus temperature of the meltable material. The first map of pixels and said second map of pixels are overlaid on each other wherein a third map of pixels is generated and is indicative of a hybrid image of the pattern of melted material.