In-situ Torsion Testing for Additive Manufacturing Build Plates
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Solution Overview
Problem
Current methods for verifying material properties of additively manufactured articles are time-consuming and costly, as they require post-processing before tensile testing can be completed, leading to delayed validation of material properties.
Innovation Solution
A torsion testing machine that allows for the application of torque to test articles still attached to the build plate, using a torsion motor, torque sensor, and strain gauge, with a data acquisition system to compare torque and twist data to determine the condition of the test articles, enabling early verification of material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If traditional tensile testing is used to verify material properties, then material property verification can be completed, but the lead time is long and post-processing is required
Solution Approach 1:
The torsion testing machine enables preliminary action by allowing material property verification to be performed while the build plate is still in the additive manufacturing system, before the parts are removed and processed. The test articles remain attached to the build plate during testing, eliminating the need for post-processing and significantly reducing lead time.
Solution Approach 2:
The torsion testing machine acts as an intermediary system that integrates material property verification capabilities within the additive manufacturing environment. It provides a mediator between the manufacturing process and quality verification, enabling testing without requiring separation of the test articles from the build plate.
2Measurement precision
If test bars are removed from the plate and machined to proper dimensions for tensile testing, then accurate material property data can be obtained, but extensive post-processing is required
Solution Approach 1:
The invention extracts the essential testing function from the traditional tensile testing process and adapts it for in-situ testing on the build plate. By using torsion testing instead of tensile testing, the system can obtain accurate material property data without requiring the test bars to be removed and machined to specific dimensions, thereby reducing post-processing complexity.
Solution Approach 2:
The system changes the testing parameter from tensile loading to torsional loading. This parameter change allows the test articles to be tested in their as-built state on the build plate, eliminating the need for post-processing while still providing accurate material property verification through torque and twist measurements.
3Reliability
If conventional tensile testing is performed after post-processing, then material properties can be verified, but the process is time-consuming and costly
Solution Approach 1:
The torsion testing machine enables preliminary action by allowing material property verification to be performed while the build plate is still in the additive manufacturing system, before the parts are removed and processed. The test articles remain attached to the build plate during testing, eliminating the need for post-processing and significantly reducing lead time.
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 solution reduces the lead time for verifying material properties, providing immediate feedback and reducing the need for extensive post-processing, thus enhancing the efficiency and cost-effectiveness of the additive manufacturing process.
Implementation Method 1
at least one torque sensor operatively connected to the torsion applicator to determine a torque applied by the torsion motor to the test article
Implementation Method 2
at least one strain gauge operatively connected to the at least one torsion applicator to determine a twist on the torsion shaft
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A system can include a torsion applicator (e.g., a torsion motor and shaft) configured to apply a torque to a test article (108) that is additively built on and attached to a build plate (103). The system can include at least one twist sensor and at least one torque sensor. A method for determining quality of an additively manufactured article or batch thereof can include torsion testing at least one additively manufactured test article that is built on and attached to a build plate (103) while the at least one test article is still attached to the build plate (103).