Ultrasonic Laser Refinement of Additive Manufactured Surfaces
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Solution Overview
Problem
Additive manufacturing systems produce components with rough surface finishes, limiting their applications in cyclical-loading environments and impeding non-destructive inspection due to stress risers and noise generation, and conventional post-processing methods are cumbersome, expensive, and ineffective for complex parts, especially for interior surfaces.
Innovation Solution
An additive manufacturing system with an ultrasonic laser emitter that emits energy off-axis from the primary energy emitter to generate ultrasonic waves, controlling grain microstructure and size by applying ultrasonic energy to the material trailing the melt pool, thereby refining the surface and preventing undesirable grain growth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional post-processing surface-finishing methods are used, then surface roughness may be reduced for simple geometries, but the process becomes cumbersome, expensive, and time consuming for complex parts
Solution Approach 1:
The patent combines the additive manufacturing process with in-situ ultrasonic grain refinement, merging two previously separate operations (additive manufacturing and surface finishing) into a single integrated process. The ultrasonic emitter is positioned within the build chamber to act on deposited material during the additive manufacturing process itself, eliminating the need for separate post-processing steps.
Solution Approach 2:
The patent replaces conventional mechanical surface-finishing equipment and methods with an ultrasonic vibration-based system. Instead of using mechanical tools to remove or reshape material surfaces, the system uses ultrasonic waves to control grain microstructure and reduce surface roughness through non-contact vibration effects.
2Manufacturing precision
If conventional post-processing methods are used, then some surface areas may be improved, but interior surfaces of complex parts remain ineffective to treat
Solution Approach 1:
The ultrasonic emitter acts as an intermediary device that can reach interior surfaces of complex geometries where conventional mechanical tools cannot access. By positioning the emitter strategically within the build chamber and using vibration-based energy transmission, the system can treat surfaces that are otherwise inaccessible to traditional post-processing equipment.
Solution Approach 2:
The patent transitions from external, contact-based surface finishing to an energy-based approach that can penetrate and act upon surfaces from different spatial dimensions. The ultrasonic waves can propagate through and act on material in ways that bypass geometric constraints, enabling treatment of interior surfaces without requiring physical access from the outside.
3Manufacturing precision
If ultrasonic vibrations are applied through baseplate contact, then grain refinement may occur, but effectiveness is reduced as component size and complexity increase
Solution Approach 1:
The patent extracts the ultrasonic emission function from the baseplate and creates a separate, dedicated ultrasonic emitter. This allows the refinement process to be decoupled from the build platform, enabling the emitter to be positioned optimally for each specific feature being built and to reach interior surfaces that would be inaccessible through baseplate contact alone.
Solution Approach 2:
The system employs dynamic positioning and control of the ultrasonic emitter, allowing it to move and adjust its position relative to the growing component. This dynamic capability enables the emitter to maintain optimal positioning for grain refinement as the component grows in size and complexity, overcoming the limitations of fixed baseplate contact methods.
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 effectively reduces surface roughness and grain size, enhancing the quality of additive manufactured components by ensuring consistent grain refinement across complex geometries, improving their structural integrity and inspection capabilities.
Implementation Method 1
An ultrasonic laser emitter is configured to emit ultrasonic laser energy onto a portion of the material to generate ultrasonic waves
Implementation Method 2
generate ultrasonic waves in relation to the portion of the material
Implementation Method 3
an energy emitter that is configured to emit energy into a material to form one or more portions of a component
Implementation Method 4
creating a weld or melt pool
Data Source
AI summary
An additive manufacturing system and method include an additive manufacturing head including an energy emitter that is configured to emit energy into a material to form one or more portions of a component. An ultrasonic laser emitter is configured to emit ultrasonic laser energy onto a portion of the material to generate ultrasonic waves in relation to the portion of the material. The ultrasonic waves control development of one or both of microstructure or size of grains in relation to the portion of the material.