In-Process Vibrational Resonance Testing for Additive Manufacturing Defects

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Solution Overview

Problem

Additive manufacturing processes face challenges in detecting anisotropy and internal defects such as micro-cracking, gas porosity, and incomplete melt within components, which can have severe consequences, especially in aerospace applications, as existing methods are either destructive or inadequate for precise quantification.

Innovation Solution

An in-process, layer-by-layer non-destructive testing system utilizing linear and nonlinear vibrational resonance, which includes a transducer to induce vibrations and a laser vibrometer to detect vibrational responses, allowing for the quantification of anisotropy and detection of internal defects within additive manufactured components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If destructive testing methods are used to evaluate structural properties, then measurement precision is improved, but the component is damaged and cannot be used

Engineering Contradiction:

Improvestructural properties measurementVSAvoidcomponent usability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent applies mechanical vibration through a transducer that generates vibrational signals to excite the additive manufactured component. By analyzing the vibrational response at different frequencies, the system can detect anisotropy and internal defects without damaging the component, thus resolving the contradiction between measurement precision and component usability

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent replaces destructive mechanical testing with a non-destructive vibrational analysis system. Instead of applying mechanical loads that cause failure, the system uses vibrational excitation and response analysis to infer structural properties, maintaining both measurement capability and component integrity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If conventional non-destructive testing is used, then component integrity is maintained, but detection precision of internal defects is insufficient

Engineering Contradiction:

Improvecomponent integrityVSAvoidinternal defects detection

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The system uses mechanical vibration at multiple frequencies to probe the component's internal structure. The vibrational response analysis reveals information about internal defects and anisotropy that conventional non-destructive methods cannot detect, improving measurement precision while maintaining component integrity

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent employs dynamic vibrational analysis instead of static testing. By exciting the component at multiple frequencies and analyzing the dynamic response, the system can detect internal defects and characterize anisotropy with high precision while keeping the component intact

Inventive Principle:

Principle #15Dynamics

3Measurement precision

If comprehensive quality evaluation is performed, then measurement precision is improved, but testing time increases

Engineering Contradiction:

Improvequality evaluation accuracyVSAvoidtesting duration

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system uses periodic vibrational excitation at multiple frequencies to efficiently gather comprehensive quality information. By sweeping through a frequency range and analyzing resonant responses, the method achieves thorough defect detection and anisotropy characterization in a single testing sequence, improving precision without excessive time loss

Inventive Principle:

Principle #19Periodic action

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 fast, sensitive, and non-destructive quality control during the additive manufacturing process, effectively identifying anisotropy and internal defects, ensuring high-quality parts by adjusting manufacturing parameters in real-time.

Implementation Method 1

a transducer attached to the plate and configured to induce vibrations in the part

Methodology Applied

Scientific EffectVibration: Vibration

Implementation Method 2

a laser vibrometer configured to detect a vibrational response of the part

Methodology Applied

Scientific EffectLaser Doppler Vibrometry: Laser Doppler Velocimetry

Implementation Method 3

in-process, layer-by-layer non-destructive testing of additive manufactured components utilizing linear and nonlinear vibrational resonance

Methodology Applied

Scientific EffectResonance: Resonance

Data Source

PatentUS11226312B1In-process, layer-by-layer non-destructive testing of additive manufactured components using linear and nonlinear vibrational resonance

Publication Date: 2022.01.18 TRIAD NATIONAL SECURITY LLC

AI summary

Provided is an additive manufacturing system capable of performing in-process, layer-by-layer non-destructive testing, the additive manufacturing system including: a plate for producing a part thereon; a transducer attached to the plate and configured to induce vibrations in the part; and a laser vibrometer configured to detect a vibrational response of the part to determine whether defect and/or anisotropy exists within the part.