Vibration Testing Apparatus for Additive Manufacturing Coupons
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Solution Overview
Problem
Monitoring material properties and defects during additive manufacturing is complex and costly, making post-construction testing of test coupons necessary to determine mechanical properties and defects, which can be time-consuming and expensive.
Innovation Solution
A testing apparatus comprising a stand, platform, clamp, actuator, displacement sensor, and circuitry that imparts a force on a test piece at specified frequencies and measures displacement, allowing for quick and accurate determination of material properties and defects, including the use of thermal imaging for defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If monitoring of material during construction is performed, then material properties and defects can be determined, but the process becomes extremely complicated and expensive
Solution Approach 1:
The patent creates test coupons during the additive manufacturing process that serve as preliminary test specimens. These coupons are manufactured alongside the main workpiece and can be tested separately, allowing material property determination without needing to monitor the main construction process in real-time. This preliminary action separates the testing function from the manufacturing process.
Solution Approach 2:
The patent uses test coupons as simplified copies or representations of the actual workpiece material. These coupons are manufactured using the same additive manufacturing process and material, allowing them to serve as surrogate specimens for testing. The coupons replicate the material properties and potential defects without requiring complex monitoring of the actual workpiece during construction.
2Measurement precision
If test pieces are constructed and tested after construction, then material properties and defects can be determined, but the process becomes time-consuming and expensive
Solution Approach 1:
Test coupons are manufactured during the additive manufacturing process itself, rather than separately after the main workpiece is completed. This preliminary creation of test specimens allows for parallel processing where the coupons are ready for testing while the main workpiece is still being manufactured, significantly reducing total testing time.
Solution Approach 2:
The patent segments the testing function by creating separate, dedicated test coupons that can be tested independently and in parallel with the main workpiece manufacturing. This segmentation allows multiple test specimens to be prepared and tested simultaneously, reducing the overall time required compared to testing a single large workpiece or waiting for complete construction before any testing can begin.
3Productivity
If traditional testing methods are used on constructed materials, then material properties can be determined, but accuracy and certainty are reduced
Solution Approach 1:
The patent designs test coupons with specific local geometries and configurations optimized for particular testing methods (e.g., cantilever beams for bending tests, specific hole patterns for ultrasonic testing). Each coupon type is tailored to extract specific material properties with high precision, rather than using generic testing approaches on arbitrary workpiece sections.
Solution Approach 2:
Test coupons are manufactured with predetermined geometries and configurations that are optimized for specific testing protocols before the actual material properties are measured. This preliminary preparation ensures that when testing occurs, the coupons are already in the ideal state for obtaining accurate and certain material property data, eliminating the need for post-manufacturing modifications or complex in-situ measurement setups.
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 rapid and precise assessment of material properties and defects, increasing accuracy and certainty, facilitating adjustments to material composition and manufacturing processes to meet desired specifications.
Implementation Method 1
an actuator adjacent to the free end and configured to impart a vibration force on the free end at a specified frequency
Implementation Method 2
a displacement sensor adjacent to the stand and configured to measure a displacement of the coupon
Data Source
AI summary
A testing apparatus may include a stand having an aperture and a platform adjacent to the aperture, a clamp adjacent to the platform and configured to hold a coupon, and an actuator within the aperture. The actuator is configured to impart a first force on the platform and the coupon at a specified frequency. The testing apparatus may also include a displacement sensor adjacent to the stand and configured to measure a displacement of the coupon and circuitry connected to the actuator and the displacement sensor with the circuitry configured to collect data from the actuator and the displacement sensor.