Thermal Energy Density Mapping for In-Process Additive Manufacturing Control
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Solution Overview
Problem
Current additive manufacturing processes lack non-destructive methods for accurately verifying the mechanical, geometrical, and metallurgical properties of production parts, as conventional quality assurance testing often requires destructive testing, which is not applicable to production parts.
Innovation Solution
The implementation of optical sensing techniques to track in-process physical phenomena and determine thermal energy density (TED) during additive manufacturing, using sensors that monitor energy radiated from the build plane, allowing for real-time adjustments to process parameters to prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional quality assurance testing is used to verify part properties, then measurement accuracy is improved, but the part is destroyed
Solution Approach 1:
The patent replaces mechanical/physical contact-based destructive testing methods with optical sensing systems that use light (electromagnetic radiation) to measure thermal energy density and infer material properties non-destructively during the additive manufacturing process
Solution Approach 2:
The patent introduces thermal energy density measurements as an intermediary parameter that correlates with final material properties. By measuring TED during manufacturing, the system infers mechanical, geometrical, and metallurgical properties without directly testing the finished part
2Device complexity
If optical sensing is implemented to enable non-destructive testing, then device complexity is improved, but measurement precision deteriorates
Solution Approach 1:
The patent implements feedback control by continuously monitoring thermal energy density during additive manufacturing and using this information to adjust process parameters in real-time, ensuring material properties remain within specified tolerances
Solution Approach 2:
The patent replaces complex post-manufacturing inspection equipment with integrated optical sensors that measure thermal radiation during the manufacturing process itself, simplifying the overall quality assurance system
3Manufacturing precision
If real-time process monitoring is implemented, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The patent implements continuous monitoring of thermal energy density during the additive manufacturing process without interrupting material deposition or energy source scanning, maintaining continuous production flow while gathering quality data
Solution Approach 2:
The patent replaces physical intervention methods (such as stopping to measure or manually adjust parameters) with non-contact optical sensing that operates simultaneously with the manufacturing process
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 non-destructive quality inference and process control, reducing discontinuities in the melt pool and improving the accuracy of additive manufacturing by identifying potential defects and adjusting energy source parameters in real-time, thus enhancing the quality and consistency of produced parts.
Implementation Method 1
measuring an amount of energy radiated from the build plane during each of the plurality of scans using an optical sensor monitoring the build plane
Implementation Method 2
the scanning energy source melts the incrementally added powder by welding regions of the powder layer creating a moving molten region, hereinafter referred to as the melt pool
Implementation Method 3
the scanning energy source melts the incrementally added powder by welding regions of the powder layer creating a moving molten region
Data Source
AI summary
This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensor; determining an area of the build plane traversed during the scans; determining a thermal energy density for the area of the build plane traversed by the scans based upon the amount of energy radiated and the area of the build plane traversed by the scans; mapping the thermal energy density to one or more location of the build plane; determining that the thermal energy density is characterized by a density outside a range of density values; and thereafter, adjusting subsequent scans of the energy source across or proximate the one or more locations of the build plane.