RT Pore Mapping for Additive Manufacturing Defect Compliance
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Solution Overview
Problem
Additive manufacturing processes like Wire Arc Additive Manufacturing (WAAM) face challenges in efficiently detecting and evaluating porosity defects, which can compromise the structural integrity of manufactured articles, due to the large number of parameters involved and the manual, time-consuming nature of traditional non-destructive evaluation methods.
Innovation Solution
An automated robotic inspection system using radiographic testing (RT) imaging, machine learning models like U-Net, and user interfaces for porosity detection, which generates pore maps and identifies rejectable defects based on quality metrics, reducing human intervention and speeding up the evaluation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual non-destructive evaluation methods are used to detect porosity defects, then inspection accuracy can be maintained, but inspection time increases significantly and productivity decreases
Solution Approach 1:
The patent replaces manual visual inspection with an automated image processing system that uses radiographic testing images. The system automatically processes RT images through algorithms to detect, measure, and evaluate porosity defects, eliminating the need for manual analysis while maintaining detection accuracy and significantly reducing inspection time.
Solution Approach 2:
The inspection system performs self-service by automatically analyzing its own output images without requiring human intervention. The image processing system independently completes the entire inspection workflow from image acquisition to defect evaluation and compliance determination, making the system self-sufficient and highly efficient.
2Reliability
If traditional manual inspection methods are used, then detailed defect evaluation can be performed, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent substitutes manual defect evaluation with automated image processing algorithms that systematically analyze RT images. The system automatically identifies pores, measures their characteristics, evaluates compliance against standards, and generates reports, providing thorough evaluation without time consumption.
Solution Approach 2:
The image processing system operates continuously without interruption or fatigue. Unlike manual inspection that requires breaks and varies in speed, the automated system maintains constant processing speed and thoroughness, continuously analyzing images and generating results without loss of time or attention.
3Productivity
If automated image processing is implemented, then inspection speed increases, but system complexity increases
Solution Approach 1:
The patent implements a universal image processing system that handles multiple functions within a single integrated platform. The system performs image acquisition, processing, defect detection, measurement, compliance evaluation, and report generation all through one unified system, reducing overall complexity compared to having separate specialized systems for each function.
Solution Approach 2:
The patent introduces an intermediary image processing system that acts as a mediator between radiographic testing and final compliance determination. This intermediate layer automatically processes RT images, identifies defects, and evaluates them against standards, simplifying the overall workflow by providing a dedicated processing layer that manages complexity.
4Adaptability or versatility
If manual inspection is performed, then flexibility in defect identification can be maintained, but consistency and repeatability decrease
Solution Approach 1:
The patent uses parameter changes by allowing the image processing system to adjust detection thresholds, measurement criteria, and evaluation parameters based on the specific inspection requirements and standards. The system can modify its parameters to adapt to different defect types and severity levels while maintaining consistent and repeatable results through programmed logic rather than human variability.
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
The system provides rapid, accurate, and ISO-compliant porosity detection, reducing manual inspection time by up to 50% and enabling efficient quality control in additive manufacturing, particularly for aerospace applications.
Implementation Method 1
a radiographic testing (RT) imaging system mounted to the robotic arm
Data Source
AI summary
A process can obtain a RT image of an article from the RT imaging system, the article comprising a reference feature, identify a first portion and a second portion of the first RT image, wherein the first portion and the second portion overlap, and classify each pixel in the first portion and the second portion using a pore classification model. A pore map can then be generated and mapped onto the article based on data received from the at least one sensor. A process can identify rejected regions on the pore map, wherein the rejected regions exceed a rejection threshold based on predefined rules. These rejected regions can then be displayed.