Powder-Bed Irradiation Sequence Planning for Shielding Gas Control
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Solution Overview
Problem
Existing methods for locally selective irradiation of a working region with energy beams in additive manufacturing are hindered by interference between adjacent irradiation regions due to shielding gas flow, leading to reduced productivity and efficiency.
Innovation Solution
A method for planning the irradiation sequence using two sequence criteria: irradiating regions with smaller transverse axis coordinates before larger ones and larger flow axis coordinates before smaller ones, allowing the coating process to overlap with ongoing irradiation, thus avoiding interference and enabling continuous manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If irradiation regions are processed sequentially against the shielding gas flow direction, then interference from material carryout is avoided, but the coating device must wait for irradiation completion reducing productivity
Solution Approach 1:
The method determines an optimized irradiation sequence in advance that allows the coating device to begin applying the next powder material layer before the current irradiation is fully complete. This preliminary planning enables overlapping of coating and irradiation operations, eliminating idle waiting time while maintaining irradiation quality through the predetermined sequence that accounts for shielding gas flow direction.
Solution Approach 2:
The invention enables continuous manufacturing by allowing the coating device to operate continuously without waiting for irradiation to complete. The next powder material layer is applied during the irradiation of the current layer, ensuring that both coating and irradiation operations proceed in an overlapping manner, thereby maximizing equipment utilization and productivity.
2Area of stationary object
If multiple energy beams operate in neighboring displacement regions, then irradiation coverage is improved, but interference between adjacent beams reduces time efficiency
Solution Approach 1:
The method predetermines an optimized irradiation sequence that coordinates multiple energy beams operating in neighboring displacement regions. By planning the sequence in advance, the system can switch between beams or overlap their operations without introducing waiting times, thereby maintaining both comprehensive irradiation coverage and high time efficiency.
Solution Approach 2:
The invention enables continuous irradiation coverage by coordinating multiple energy beams to operate in sequence or overlap without idle waiting time. The predetermined irradiation sequence ensures that when one beam completes its region, another beam is ready to immediately begin or continue irradiation, eliminating gaps and maintaining continuous productive action across the entire working region.
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 approach enhances manufacturing productivity by allowing simultaneous coating and irradiation, reducing the need for waiting times and preventing interference between adjacent irradiation regions, resulting in efficient component production.
Implementation Method 1
locally selective irradiation of a working region with at least one energy beam in order to produce, by means of the energy beam, at least one component layer by layer
Implementation Method 2
predetermined shielding gas flow direction above the working region
Data Source
AI summary
A method provides for planning a locally selective irradiation of a working region with at least one energy beam in order to produce, by the at least one energy beam, at least one component layer by layer from a plurality of powder material layers of a powder material arranged chronologically one after another in a layer sequence in the working region. The method includes: determining, for at least one powder material layer based on at least two sequence criteria, a chronological irradiation sequence of an irradiation of a plurality of irradiation regions with the at least one energy beam; using, as a first sequence criterion, a first irradiation chronology; using, as a second sequence criterion, a second irradiation chronology; and obtaining an irradiation plan for the locally selective irradiation of the working region with the at least one energy beam in the at least one powder material layer.