SYSTEMS FOR QUALITY MONITORING OF ADDITIVE MANUFACTURING

• US 20170038342A1
• Filed: 08/05/2015
• Published: 02/09/2017
• Est. Priority Date: 08/05/2015
• Status: Active Grant

• Current Assignee: Collins Engine Nozzles Incorporated
• Original Assignee: Delavan Incorporated (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Clavette, Patrick L., Klecka, Michael A., Nardi, Aaron T., Ojard, Greg C.
• Granted Patent: US 10,295,502 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 10/32 of the atmosphere, e.g. composition or pressure in a building chamber
• CPC Class Codes: B22F 10/38 to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2202/01 Use of vibrations
• CPC Class Codes: B22F 2203/00 Controlling
• CPC Class Codes: B22F 2203/03 for feed-back
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B33Y 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: C23C 24/04 Impact or kinetic deposition of particles
• CPC Class Codes: G01N 2291/0231 Composite or layered materials
• CPC Class Codes: G01N 2291/0251 Solidification, icing, curing composites, polymerisation
• CPC Class Codes: G01N 29/043 in the interior, e.g. by shear waves
• CPC Class Codes: G01N 29/0618 synchronised with scanning, e.g. in real-time
• CPC Class Codes: G01N 29/14 using acoustic emission techniques echo of particles G01N29/046; measuring mechanical vibrations or acoustic waves in solids in general G01H1/00
• CPC Class Codes: G01N 29/4454 Signal recognition, e.g. specific values or portions, signal events, signatures
• CPC Class Codes: G05B 2219/37337 Noise, acoustic emission, sound
• CPC Class Codes: G05B 2219/37351 Detect vibration, ultrasound
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

A system for quality monitoring of additive manufacturing includes an acoustic emission (AE) sensor configured to be attached to an additive manufacturing substrate and to output a sensor signal indicative of acoustic vibrations received at the AE sensor and an AE module. The AE module is configured to receive the sensor signal from the AE sensor and process the sensor signal to determine at least one characteristic of an additive manufacturing process and/or an additively manufactured article.

Claims

1. A system for quality monitoring of additive manufacturing, comprising:

an acoustic emission (AE) sensor configured to be attached to an additive manufacturing substrate and to output a sensor signal indicative of acoustic vibrations received at the AE sensor; and

an AE module configured to;

receive the sensor signal from the AE sensor; and

process the sensor signal to determine at least one characteristic of an additive manufacturing process and/or an additively manufactured article.

2. The system of claim 1, further comprising at least one additional AE sensor operatively connected to the AM module.

3. The system of claim 1, wherein the AE module is configured to receive the sensor signal in real time during the additive manufacturing process.

4. The system of claim 1, wherein the AE module is configured to process the sensor signal in real time.

5. The system of claim 1, wherein the at least one characteristic of the additively manufactured article includes coat delamination, coat cracking, or coat material quality.

6. The system of claim 5, wherein the coat material quality includes at least one of coat particle size or composition.

7. The system of claim 1, wherein the at least one characteristic of the additive manufacturing process includes an amount and/or a quality of at least one of a powder supply or an injection gas supply.

8. The system of claim 1, further comprising a spray controller operatively connected to the AE module to receive AE module data from the AE module, wherein the spray controller is configured to be operatively connected to at least one of a sprayer, a powder supply, or an injection gas supply to control a powder spray onto the substrate.

9. The system of claim 8, wherein the AE module data includes computer executable instruction for the spray controller to start, stop, and/or otherwise modify the powder spray based on the at least one characteristic of an additive manufacturing process and/or an additively manufactured article.

10. A method for monitoring a quality of additive manufacturing, comprising:

receiving a sensor signal from an acoustic emissions (AE) sensor; and

processing the sensor signal to determine at least one characteristic of an additive manufacturing process and/or an additively manufactured article.

11. The method of claim 10, further comprising receiving a sensor signal from at least one additional AE sensor.

12. The method of claim 10, wherein receiving the sensor signal includes receiving the sensor signal in real time during the additive manufacturing process.

13. The method of claim 10, wherein processing the sensor signal includes processing the sensor signal in real time.

14. The method of claim 10, wherein the at least one characteristic of the additively manufactured article includes coat delamination, coat cracking, or coat material quality.

15. The method of claim 14, wherein the coat material quality includes at least one of coat particle size or composition.

16. The method of claim 10, wherein the at least one characteristic of the additive manufacturing process includes an amount and/or a quality of at least one of a powder supply or an injection gas supply.

17. The method of claim 10, further comprising outputting data to a spray controller, wherein the spray controller is configured to be operatively connected to at least one of a sprayer, a powder supply, or an injection gas supply to control a powder spray onto the substrate.

18. The method of claim 17, wherein outputting data includes instructing the spray controller to start, stop, and/or otherwise modify the powder spray based on the at least one characteristic of an additive manufacturing process and/or an additively manufactured article.