Monolithic Multi-Axis Cantilever for Non-Destructive AM Testing
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Solution Overview
Problem
Existing test artifacts for characterizing material properties of additively manufactured structures are typically destructively tested, which does not account for the unique behavior of these materials and results in uncertainty and the need for multiple test setups, whereas there is a requirement for non-destructive evaluation to assess mechanical properties and ensure build quality.
Innovation Solution
A multi-axis linear flexural cantilever test artifact designed for non-destructive evaluation, featuring a support frame with cantilevers of varying thickness and height, allowing for modal analysis and characterization of multiple mechanical and material properties such as Young's modulus, shear modulus, and fatigue properties, enabling repeat testing without assembly and rotation, suitable for additive manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional destructive testing methods are used to characterize material properties, then mechanical properties such as Young's modulus and yield strength can be determined, but the test artifact is destroyed and cannot be reused, leading to increased time and resource requirements for multiple tests
Solution Approach 1:
The patent creates a digital twin or virtual model of the test artifact that can be tested repeatedly without physical destruction. The virtual model replicates the mechanical properties and response characteristics, allowing multiple test scenarios to be evaluated on the same artifact design without requiring multiple physical specimens.
Solution Approach 2:
The patent replaces physical destructive mechanical testing with non-destructive evaluation methods such as modal analysis, vibration testing, or acoustic emission techniques. These methods substitute the traditional mechanical loading that destroys the specimen with fields-based measurements that preserve the artifact for repeated use.
2Adaptability or versatility
If multiple test setups are used to characterize different material properties, then comprehensive material characterization can be achieved, but the device complexity and number of required artifacts increase
Solution Approach 1:
The patent designs a single test artifact with multiple functional capabilities that can be used across different test setups and configurations. The artifact includes various mounting interfaces, sensing locations, and geometric features that enable it to serve multiple characterization purposes (static testing, dynamic testing, modal analysis) without requiring separate specialized artifacts for each test type.
Solution Approach 2:
The test artifact is divided into modular sections or features that can be independently utilized for different testing purposes. This segmentation allows specific portions of the artifact to be engaged for particular measurements while leaving other portions available for different types of tests, reducing the need for completely separate artifacts.
3Stability of the object's composition
If traditional test artifacts designed for wrought materials are used for additively manufactured materials, then standardization is maintained, but the unique behavior and anisotropic properties of additively manufactured materials are not adequately captured
Solution Approach 1:
The patent incorporates localized features or variations in the test artifact design that specifically address the anisotropic and heterogeneous nature of additively manufactured materials. This may include direction-dependent geometric features, varied thickness regions, or localized sensing elements that capture material behavior in different build orientations and locations, going beyond the homogeneous assumptions of traditional wrought material test artifacts.
Data Source
AI summary
The present invention relates to an additively manufactured (AM), monolithic, multi-axis linear flexural cantilever test artifact. The artifact is monolithic in that is it one continuous part with no assembly. The artifact can be non-destructively evaluated and includes a support frame, cantilevers, and a mount.