3D Component Melt Pool Monitoring for In-Process Quality Mapping
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Solution Overview
Problem
Existing laser melting processes lack effective methods for real-time evaluation and visualization of component quality during the production of three-dimensional components, making it difficult to ensure optimal fusion, temperature profiles, and component density, which can lead to material failures and user complaints.
Innovation Solution
A method and device that capture and store sensor values with coordinate data for displaying component quality in 2D or 3D representations, allowing for immediate visualization and analysis of the melt pool dimensions, temperature, and energy influx, enabling operators to identify and address deviations in solidification and density during the building process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor values are captured and stored with coordinate data for quality evaluation, then component quality monitoring capability is improved, but device complexity increases
Solution Approach 1:
The patent embeds the sensor device within the laser beam path, nesting the quality monitoring function inside the existing manufacturing system. The sensor is positioned to detect radiation from the melt region while the laser processes the material, allowing quality evaluation without adding external complex equipment. Coordinate data is stored alongside sensor values, creating a nested data structure that integrates measurement information with production data.
Solution Approach 2:
The patent introduces an intermediary data processing layer that captures sensor values, associates them with coordinate information, and stores them for later evaluation. This intermediary system acts as a mediator between the laser melting process and quality analysis, converting raw sensor data into evaluable quality metrics without requiring direct complex interaction between manufacturing and measurement systems.
2Manufacturing precision
If real-time sensor monitoring is implemented during laser melting, then component quality control is improved, but loss of time in processing increases
Solution Approach 1:
The sensor device operates continuously during the laser melting process, capturing radiation from the melt region in real-time without interrupting the manufacturing workflow. The monitoring function runs parallel to the production process, ensuring continuous quality data collection while maintaining uninterrupted material processing. This eliminates the need for separate measurement steps that would add time to the overall process.
Solution Approach 2:
The patent implements a feedback mechanism where sensor values captured during laser melting are stored with coordinate data and used for evaluating component quality. The system provides feedback on melt pool characteristics and solidification quality, enabling real-time process optimization without requiring process interruptions. The feedback loop allows continuous adjustment of laser parameters based on actual melt region conditions.
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 monitoring and post-processing analysis of component quality, preventing material failures by providing immediate feedback on fusion, temperature, and density, allowing for adjustments to avoid defects and ensuring compliance with design specifications.
Implementation Method 1
a sensor device (6) for capturing electromagnetic radiation which is emitted or reflected by the melt region (5) and interacting with an optical system that follows the laser beam
Implementation Method 2
a laser, the focused laser beam of which impinges on the powder surface and causes the powder to melt within a melt zone
Implementation Method 3
causes the powder to melt within a melt zone created by point- and/or line-shaped energy influx
Implementation Method 4
the component is produced by successive solidifying of individual layers of building material which can be solidified by the action of radiation
Data Source
AI summary
Sensor values captured by a sensor device are determined, one or more regions of a three-dimensional component having a deviation from an intended value are determined based at least in part on build coordinates for additively manufacturing the three-dimensional component corresponding to the sensor values, and a quality of the three-dimensional component is evaluated based at least in part on the one or more regions of the three-dimensional component having a deviation from the intended value. The sensor values correspond to an electromagnetic spectrum emitted by a melt pool formed by exposing a powder bed to a beam of radiation emitted from a laser apparatus, with the beam of radiation generating the melt pool in a melt region of the powder bed.