Systems and methods for measuring radiated thermal energy during an additive manufacturing operation

• US 10,639,745 B2
• Filed: 02/21/2019
• Issued: 05/05/2020
• Est. Priority Date: 02/21/2018
• Status: Active Grant

• Current Assignee: Divergent Technologies, Inc.
• Original Assignee: Sigma Labs, Inc.
• Inventors: Beckett, Darren, Betts, Scott, Piltch, Martin, Madigan, R. Bruce, Jacquemetton, Lars, Wikle, Glenn, Cola, Mark J., Dave, Vivek R., Castro, Alberto M., Frye, Roger
• Primary Examiner(s): Ross, Dana
• Assistant Examiner(s): Samuels, Lawrence H
• Application Number:
  US16/282,004
• Publication Number:
  US 20190255654A1
• Time in Patent Office: 439 Days
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/31 Calibration of process steps or apparatus settings, e.g. before or during manufacturing
• CPC Class Codes: B23K 15/0086 welding for purposes other than joining, e.g. built-up welding
• CPC Class Codes: B23K 2103/10 Aluminium or alloys thereof
• CPC Class Codes: B23K 2103/14 Titanium or alloys thereof
• CPC Class Codes: B23K 26/03 Observing, e.g. monitoring, the workpiece
• CPC Class Codes: B23K 26/032 using optical means
• CPC Class Codes: B23K 26/034 Observing the temperature of the workpiece
• CPC Class Codes: B23K 26/0643 comprising mirrors
• CPC Class Codes: B23K 26/082 Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
• CPC Class Codes: B23K 26/34 Laser welding for purposes other than joining
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B23K 26/354 by melting
• CPC Class Codes: B23K 31/125 Weld quality monitoring
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes

Abstract

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 sensing system that monitors two discrete wavelengths associated with a blackbody radiation curve of the layer of powder; determining temperature variations for an area of the build plane traversed by the scans based upon a ratio of sensor readings taken at the two discrete wavelengths; determining that the temperature variations are outside a threshold range of values; and thereafter, adjusting subsequent scans of the energy source across or proximate the area of the build plane.

Claims

1. An additive manufacturing method, comprising:

identifying spectral peaks associated with material properties of a batch of powder;

selecting a first wavelength and a second wavelength spaced apart from the first wavelength, the first wavelength and the second wavelength being offset from the identified spectral peaks;

generating a plurality of scans of an energy source across a layer of the batch of powder disposed upon a build plane during an additive manufacturing operation;

measuring an amount of energy radiated from the build plane at the first wavelength;

measuring an amount of energy radiated from the build plane at the second wavelength;

determining variations in temperature of an area of the build plane traversed by the plurality of scans based upon a ratio of energy radiated at the first wavelength to energy radiated at the second wavelength;

determining that the variations in temperature are outside a threshold range of values; and

thereafter, adjusting subsequent scans of the energy source across or proximate the area of the build plane.

2. The additive manufacturing method of claim 1 wherein the amount of energy radiated from the build plane at the first wavelength is measured by an optical sensor monitoring wavelengths within 5 nm of the first wavelength.

3. The additive manufacturing method of claim 2, wherein the optical sensor comprises at least one of a photodiode, a pyrometer, or an imaging sensor.

4. The additive manufacturing method of claim 1 further comprising determining the area of the build plane traversed by:

determining a start point of a first scan of the plurality of scans;

determining an end point of the first scan; and

determining a length of the first scan by calculating a distance between the start point and the end point.

5. The additive manufacturing method of claim 1, further comprising:

transmitting a control signal associated with a process parameter when the variations in temperature are determined to be outside of the threshold range of values.

6. The additive manufacturing method of claim 1 wherein the energy source corresponds to at least one of a laser or an electron beam.

7. The additive manufacturing method of claim 1 further comprising:

mapping a thermal energy density to locations within a part being formed by the additive manufacturing operation by;

receiving energy source drive signal data indicating a path of the energy source across the build plane; and

determining a location of each of the plurality of scans using the energy source drive signal data.

8. The additive manufacturing method of claim 1 further comprising:

receiving position data associated with the energy source.

9. The additive manufacturing method of claim 1, further comprising:

receiving energy source drive signal data, wherein the energy source drive signal data indicates when the energy source is turned on and when the energy source is turned off.

10. An additive manufacturing method, comprising:

identifying spectral peaks associated with material properties of a batch of powder;

selecting a first wavelength and a second wavelength spaced apart from the first wavelength, the first wavelength and the second wavelength being offset from the identified spectral peaks;

generating a plurality of scans of an energy source across a layer of the batch of powder on a build plane;

generating sensor readings during each of the plurality of scans using an optical sensing system that monitors the first wavelength and the second wavelength;

determining variations in temperature across the build plane during the plurality of scans using a ratio of the sensor readings collected at the first wavelength to the sensor readings collected at the second wavelength;

determining when the variations in temperature are outside a threshold range of values; and

thereafter, adjusting an output of the energy source.

11. The additive manufacturing method of claim 10, wherein the ratio of sensor readings from the first and second wavelengths is used to determine an absolute temperature of a portion of the layer of the batch of powder.

12. The additive manufacturing method of claim 10, wherein the energy source is a laser configured to output light having a laser wavelength and wherein the first and second wavelengths do not overlap with the laser wavelength.

13. The additive manufacturing method of claim 10, determining a grid region including the plurality of scans comprises:

receiving energy source drive signal data indicating a path of the energy source across the build plane; and

defining a location, shape and size of the grid region based upon the energy source drive signal data.

14. The additive manufacturing method of claim 13, wherein the energy source drive signal data includes a distance between two or more scans of the plurality of scans.

15. An additive manufacturing method, comprising:

identifying spectral peaks associated with material properties of a batch of powder;

selecting a first wavelength and a second wavelength spaced apart from the first wavelength, the first wavelength and the second wavelength being offset from the identified spectral peaks;

generating a plurality of scans of an energy source across a layer of powder on a build plane;

generating sensor readings during each of the plurality of scans using an optical sensing system that monitors the first and second wavelengths during the plurality of scans;

for each of the plurality of scans, mapping portions of each of the sensor readings to a respective one of a plurality of regions of the build plane;

for each of the plurality of regions;

characterizing temperature variations within the region based on a ratio of the sensor readings taken at the first wavelength and the sensor readings taken at the second wavelength;

determining that the temperature variations associated with one or more of the plurality of regions are outside a threshold range of values; and

thereafter, adjusting an output of the energy source.

16. The additive manufacturing method as recited in claim 15, wherein the first wavelength is larger than a wavelength associated with a peak of a blackbody radiation curve associated with the batch of powder for an operating temperature associated with the additive manufacturing method and the second wavelength is smaller than the wavelength associated with the peak of the blackbody radiation curve.

17. The additive manufacturing method of claim 16, wherein a ratio of an intensity of the first wavelength to an intensity of the second wavelength increases with a temperature of a melt pool generated by the energy source.

18. The additive manufacturing method of claim 15 wherein the plurality of regions are arranged in a grid across the build plane.

19. The additive manufacturing method of claim 18, wherein the build plane is characterized by an area equal to an area of the grid.

20. The additive manufacturing method of claim 18, wherein the regions are distributed evenly across the build plane.