Method and apparatus for examination of objects and structures

• US 20070176312A1
• Filed: 01/22/2007
• Published: 08/02/2007
• Est. Priority Date: 02/01/2006
• Status: Abandoned Application

• Current Assignee: Rolls-Royce PLC (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce PLC (Rolls-Royce Holdings Plc)
• Inventors: Clark, Daniel, Wright, David C
• Application Number:
  US11/655,878
• Publication Number:
  US 20070176312A1
• Time in Patent Office: Days
• US Class Current: 264/40.100
• CPC Class Codes: B22F 10/10 Formation of a green body
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/36 of energy beam parameters
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B23K 15/0086 welding for purposes other than joining, e.g. built-up welding
• CPC Class Codes: B23K 2101/001 Turbines
• CPC Class Codes: B23K 26/34 Laser welding for purposes other than joining
• CPC Class Codes: B23K 35/0244 Powders, particles or spheres; Preforms made therefrom
• 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 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

Defects within structures formed by deposition processes can be relatively expensive, particularly as previously non-destructive testing was performed only once the component had been formed. By in-situ continuous or intermittent sequential non-destructive testing, early notice of defects can be provided. Such early notice may allow rejection of the part-formed component, correction of the errors causing the defect, or through an auto-correction process adjustment of the deposition devices or otherwise to improve component quality. Generally, deposition processes provide for provision of a layer of material which is consolidated in order to form an object component through use of a consolidation device. By providing a non-destructive testing device which either continuously inspects the layers of consolidated component or sequentially inspects the object component, it is possible as indicated to provide an early identification of defect problems within a formed object component.

Claims

1. A method for producing an object or structure, the method comprising:

(i) providing a layer of powder material;

(ii) irradiating selected areas of the layer to combine the powder material in the selected areas;

(iii) providing a further layer of powder material overlying the previously provided layer;

(iv) repeating step (ii) to combine the powder material in selected areas of the further layer and to combine the powder material in the selected areas of the further layer with the combined powder material in the underlying layer;

(v) successively repeating steps (iii) and (iv) to produce an object or structure;

wherein the method comprises analysing the properties of the combined powder material of at least one layer prior to providing a further layer of powder material overlying the previously provided layer.

2. A method according to claim 1, wherein said analysing step comprises analysing the properties of the combined powder material of a provided layer and one or more underlying layers.

3. A method according to claim 1, wherein step (ii) comprises moving a laser beam across the selected areas to combine the powder material in the selected areas.

4. A method according to claim 3, wherein the method comprises controlling the properties of the laser beam in response to the analysed properties of the combined powder material of the at least one layer.

5. A method according to claim 4, wherein the step of controlling the properties of the laser beam comprises controlling the power of the laser beam.

6. A method according to claim 4, wherein the step of controlling the properties of the laser beam comprises controlling the speed of movement of the laser beam across the selected areas of the layer of powder material.

7. A method according to claim 4, wherein the step of controlling the properties of the laser beam comprises controlling the focus of the laser beam on the surface of the layer of powder material.

8. A method according to claim 1, wherein the analysing step comprises non-destructively analysing the properties of the combined powder material of the at least one layer.

9. A method according to claim 8, wherein the non-destructive analysis step comprises analysing the material properties of the combined powder material of the at least one layer using a non-contact ultrasonic testing technique.

10. A method according to claim 9, wherein the step of analysing the combined powder material of the at least one layer using a non-contact ultrasonic testing technique comprises inducing an ultrasonic wave in the at least one layer and detecting the motion of the ultrasonic wave, the motion of the ultrasonic wave being indicative of the properties of the at least one layer.

11. A method according to claim 8, wherein the non-destructive analysis step comprises analysing the material properties of the combined powder material of the at least one layer using an eddy current testing technique.

12. A method according to claim 11, wherein the step of analysing the combined powder material of the at least one layer using an eddy current testing technique comprises inducing an eddy current

13. A method as claimed in claim 1 wherein the method can separate layers of material of a different type.

17. A method as claimed in claim 1 wherein non-destructive testing/inspecting is provided during depositing and/or consolidation of further layers of material.

31. An object formed by a method as claimed in claim 1.

14. A method of forming objects by deposition, the method comprising depositing layers of material, consolidating one layer upon another layer of material to form the object and non-destructively testing/inspecting consolidation to at least a depth of one layer of material relative to depositing and/or consolidation of further layers of material.

15. A method as claimed in claim 14 wherein the non-destructive testing is continuous.

16. A method as claimed in claim 14 wherein non-destructive testing/inspecting is intermittent.

18. A method as claimed in claim 14 wherein the material is a powder.

19. A method as claimed in claim 14 wherein consolidation is by means of a laser.

20. A method as claimed in claim 19 wherein the non-destructive testing/inspecting is by adjusting the laser for ultrasound response.

21. A method as claimed in claim 19 wherein the laser is adjusted for consolidation dependent upon the non-destructive testing/inspecting.

22. A method as claimed in claim 14 wherein the non-destructive testing/inspection is by electrical eddy current analysis of consolidation of layers of material.

23. A method as claimed in claim 14 wherein consolidation is localised in a consolidation zone about over-laying layers of material.

24. A method as claimed in claim 23 wherein the consolidation zone moves along overlaying layers as the method is performed.

25. A method as claimed in claim 24 wherein the non-destructive testing/inspection is performed at an inspection site about the periphery of the consolidation zone.

26. A method as claimed in claim 25 wherein the inspection site is from a few millimetres to 5 cm displaced from the consolidation zone.

27. A method as claimed in claim 14 wherein the non-destructive testing/inspection is volumetric and extends to a depth beyond one layer of material.

28. A method as claimed in claim 14 wherein the non-destructive testing/inspection is substantially surface orientated.

29. An apparatus for forming objects by deposition, the apparatus comprising a material deposition device for depositing layers of material, a consolidation device for consolidating layers of material and a non-destructive testing device for non-destructively testing and/or inspecting consolidation to at least one layer of material.

32. An object formed by an apparatus as claimed in claim 29.

30. A method of testing a deposition process of forming objects where non-destructive testing is performed upon layers of material deposited and consolidated in order to form an object.

33. An object formed by a method as claimed in claim 30.