Powder Mixture Concentration Detection for Additive Manufacturing
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Solution Overview
Problem
Current additive production methods for turbomachine components face challenges in achieving high-quality components due to uncertainties in material concentration and composition, leading to potential irregularities and reduced quality.
Innovation Solution
A method involving a high-energy beam to detect brightness values from a powder mixture, allowing for the accurate determination of material concentration using a detection unit and analysis unit, which adjusts control parameters for improved component production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive production methods are used without material concentration detection, then the manufacturing process is simpler and faster, but the component quality and material composition precision deteriorate
Solution Approach 1:
The detection unit measures the brightness of the powder mixture before the high-energy beam melts it, allowing the concentration of materials to be determined in advance. This preliminary measurement enables quality control without adding significant complexity to the manufacturing process, as the measurement is taken during the natural powder delivery phase before processing begins.
Solution Approach 2:
The patent replaces complex mechanical material analysis systems with an optical detection system. By measuring the brightness of the powder mixture under high-energy beam irradiation and comparing it to reference brightness values, the system determines material concentration optically rather than through complex mechanical or chemical analysis methods.
2Reliability
If material concentration is not monitored, then the production process is faster and less complex, but the reliability and consistency of component properties deteriorate
Solution Approach 1:
The system establishes a feedback loop by measuring the brightness of the powder mixture, comparing it to reference brightness values stored in memory, and using this information to monitor material concentration. This feedback mechanism ensures consistent material composition while maintaining production speed, as the measurement and comparison process is integrated into the existing manufacturing flow without requiring additional processing time.
3Measurement precision
If brightness values are measured during high-energy beam irradiation, then material concentration can be determined, but the detection system becomes more complex and energy consumption increases
Solution Approach 1:
The patent merges the detection function with the existing high-energy beam processing system. The same high-energy beam that melts the powder mixture also serves to illuminate it for brightness measurement, eliminating the need for a separate detection energy source. This integration allows accurate material concentration determination without additional energy consumption from dedicated detection 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 the production of high-quality turbomachine components by ensuring precise material composition and geometry, detecting deviations and imperfections, and regulating the manufacturing process accordingly.
Implementation Method 1
guiding a high-energy beam generated by a radiation source over a surface of the powder mixture; detecting by a detection unit at least one brightness value of at least one subregion of the surface, which is irradiated by the high-energy beam
Data Source
AI summary
A method for ascertaining the concentration of at least one material in a powder mixture used as starting material for the production of a component in an additive production method, comprising:providing the powder mixture having at least two different materials;guiding a high-energy beam generated by a radiation source over the surface of the powder mixture;detecting by a detection unit at least one brightness value of at least one subregion of the surface irradiated by the high-energy beam during the irradiation;ascertaining by an analysis unit the concentration of at least one material in the powder mixture depending on the detected at least one brightness value and at least one predetermined reference brightness value for a concentration and/or a concentration range of the material.