CN106990114B - Additive manufacturing defect detection method and additive manufacturing device - Google Patents
Additive manufacturing defect detection method and additive manufacturing device Download PDFInfo
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- 238000001514 detection method Methods 0.000 title claims abstract description 51
- 238000003384 imaging method Methods 0.000 claims abstract description 103
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
- G01N23/20—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by using diffraction of the radiation by the materials, e.g. for investigating crystal structure; by using scattering of the radiation by the materials, e.g. for investigating non-crystalline materials; by using reflection of the radiation by the materials
- G01N23/203—Measuring back scattering
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
- G01N23/22—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by measuring secondary emission from the material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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Abstract
The invention belongs to the field of additive manufacturing, and discloses a defect detection method for additive manufacturing, which comprises the following steps: at least in the preheating and/or melting stage, acquiring visible light images and/or infrared images through an image shooting device and acquiring electronic imaging images through an electronic imaging device; and comparing the visible light image and/or the infrared image with the standard image after being singly or fused with the electronic imaging image, and determining that defects exist in the preheating and/or melting stage when the differences exist. The invention also discloses an additive manufacturing device which comprises a forming chamber, an image shooting device and an electronic imaging device. According to the invention, the visible light image and/or the infrared image are obtained through the image shooting device, the electronic imaging image is obtained through the electronic imaging device, and the electronic imaging image is compared with the standard image after being singly or fused, so that whether defects exist can be judged according to the comparison result, the detection is accurate, the false detection or the omission is not easy to cause, and the problem of defect detection lag existing in the existing defect detection is avoided.
Description
Technical Field
The invention relates to the technical field of additive manufacturing, in particular to a defect detection method for additive manufacturing and an additive manufacturing device.
Background
Additive manufacturing (3D printing) is a manufacturing technique that builds three-dimensional objects by continuously fusing more than one thin layer of material. Powder bed type additive manufacturing is one of the technical routes of additive manufacturing, and the basic process steps are as follows: the powder supply and paving system spreads the powder material into a thin layer on the working platform, and a beam (laser or electron beam) with high energy density scans a cross section of the three-dimensional object on the thin layer of powder; then, the working platform descends by a distance equal to the thickness of a thin powder layer, a layer of new powder is paved on the working platform, and the next section of the three-dimensional object is scanned by rays; repeating the steps until the three-dimensional object is manufactured.
Most of the existing powder bed type additive manufacturing equipment has no defect detection capability, printing section information is obtained by utilizing various detection means, defects in the forming process are predicted or detected, and the powder bed type additive manufacturing equipment is used for guiding adjustment of technological parameters in the forming process and is one of the development directions of additive manufacturing.
The prior art provides a method for capturing a visible light image or an infrared image with a camera and identifying defects by successive multi-layer comparison. The method is limited in that the image can be captured only by a detection means such as a camera, defects can be detected only by the comparison of front and rear layers, the detection method is single, the defects can be confirmed only by the multi-layer forming, and the problem of defect detection hysteresis is caused, meanwhile, the image information obtained by the same detection method is easy to cause false detection or omission detection, so that unnecessary process adjustment or even stop of forming is caused.
Disclosure of Invention
The invention aims to provide a defect detection method and device for additive manufacturing, which are used for solving the problems that defect detection is delayed in defect detection in the existing additive manufacturing process, and the obtained image information is easy to cause false detection or missing detection.
To achieve the purpose, the invention adopts the following technical scheme:
an additive manufacturing defect detection method, comprising:
at least in the preheating and/or melting stage, acquiring visible light images and/or infrared images through an image shooting device and acquiring electronic imaging images through an electronic imaging device;
and comparing the visible light image and/or the infrared image with the standard image after being singly or fused with the electronic imaging image, and determining that defects exist in the preheating and/or melting stage when the differences exist.
Preferably, the method further comprises:
determining the type of defect and the severity of the defect when the defect is present in the preheating and/or melting stage;
and judging whether additive manufacturing can be continued or not according to the type of the defect and/or the severity of the defect.
Preferably, said determining whether additive manufacturing can be continued according to the type of defect and/or the severity of the defect comprises:
when the type of the defect is not suitable for continuing additive manufacturing or the severity of the defect exceeds a preset level, the additive manufacturing cannot be continued;
additive manufacturing can continue when the type of defect can continue and/or the severity of the defect does not exceed a preset level.
Preferably, the method comprises:
while additive manufacturing can continue, the current or next process parameters in the pre-heating and/or melting stage are adjusted to reduce or repair the defect.
Preferably, the method further comprises:
and continuously comparing the visible light image and/or the infrared light image obtained for multiple times with the electronic imaging image to judge whether the defect is reduced or repaired.
Preferably, the standard image is: and generating a standard interface shape image through slice data of the three-dimensional object model, or obtaining an energy distribution image and a component distribution image through numerical simulation software, or fusing the standard interface shape image, the energy distribution image and the component distribution image to form a fused imaging image.
The invention also provides an additive manufacturing device, which comprises a forming chamber, an image shooting device arranged inside or outside the forming chamber, an electronic imaging device arranged inside or outside the forming chamber, and a control device connected with the image shooting device and the electronic imaging device, wherein the image shooting device is used for acquiring visible light images and/or infrared images in a preheating and/or melting stage, and the electronic imaging device is used for acquiring electronic imaging images in the preheating and/or melting stage.
Preferably, the image capturing device is a camera or a video camera connected to the control device.
Preferably, when the image capturing device is a camera, the camera may capture a visible light image and an infrared image by replacing the filter.
Preferably, the electronic imaging device comprises an electronic acquisition device and a signal processing device connected to the electronic acquisition device, wherein:
the electronic acquisition device is connected with the control device and is used for acquiring electronic signals generated in the preheating and/or melting stage and sending the electronic signals to the signal processing device;
the signal processing device is connected with the control device and is used for receiving and processing the electronic signals sent by the electronic acquisition device, sending the processing results to the control device and forming electronic imaging images by the control device.
According to the invention, the visible light image and/or the infrared image are obtained through the image shooting device, the electronic imaging image is obtained through the electronic imaging device, and the electronic imaging image is compared with the standard image after being singly or fused, so that whether defects exist can be judged according to the comparison result, the detection is accurate, the false detection or the omission is not easy to cause, and the problem of defect detection lag existing in the existing defect detection is avoided.
And the technological parameters can be timely adjusted according to the defects, so that the generation of the defects is reduced or the generated defects are repaired, and the yield of the forming process is increased.
Drawings
FIG. 1 is a flow chart of a method of additive manufacturing defect detection of the present invention;
FIG. 2 is a schematic illustration of a standard image in an additive manufacturing defect detection method of the present invention;
FIG. 3 is a schematic diagram of a fused imaging image of a pre-heated scanned visible light image and an electronic imaging image fused in an additive manufacturing defect detection method of the present invention;
FIG. 4 is a schematic illustration of a fused imaging image after a visible light image and an infrared image are fused in the additive manufacturing defect detection method of the present invention;
FIG. 5 is a schematic illustration of a fused imaging image of a secondary electron image obtained from an electron imaging image and a backscattered electron image fused in an additive manufacturing defect detection method of the present invention;
FIG. 6 is a schematic diagram of a fused imaging image of a visible light image, an infrared image, and an electronic imaging image fused in an additive manufacturing defect detection method of the present invention;
FIG. 7 is a schematic diagram of an apparatus for additive manufacturing according to the present invention.
In the figure:
1. a forming chamber; 2. a hopper; 3. a powder receiving box; 4. a powder spreading platform; 5. a forming cylinder; 6. a piston; 7. a scraper; 8. a radiation generator; 9. an image photographing device; 10. an electronic imaging device.
Detailed Description
The technical scheme of the invention is further described below by the specific embodiments with reference to the accompanying drawings.
The invention provides a method for detecting additive manufacturing defects, which is shown in fig. 1 and comprises the following steps:
s10, at least in the preheating and/or melting stage, a visible light image and/or an infrared image are acquired through an image shooting device, and an electronic imaging image is acquired through an electronic imaging device.
I.e. after the powder material has been laid down as a thin powder layer on the forming cylinder of the additive manufacturing device, the thin powder layer is preheated and melted by means of an electron beam.
In the preheating stage, in the process of starting preheating scanning of the thin powder layer by the electron beam, after the electron beam acts on the powder, electronic signals such as secondary electrons, auger electrons, characteristic X rays, continuous spectrum X rays, back scattering electrons, transmission electrons and the like are generated, and the electronic signals can be acquired through an electronic imaging device to obtain an electronic imaging image corresponding to each electronic signal.
In this embodiment, the electron beam performs multiple preheating scans on the thin powder layer in the preheating stage, so the electronic imaging device can continuously collect or collect the electronic signal of the last preheating scan at the end of preheating to obtain an electronic imaging image. By means of the above-mentioned electron imaging image, the forming information of the current powder thin layer can be obtained, for example, the morphology information of the current powder thin layer can be obtained by means of the electron imaging image obtained by means of the secondary electron image, and the composition information of the current powder thin layer can be obtained by means of the electron imaging image obtained by means of the back-scattered electron image. And so on, the electronic imaging image corresponding to each electronic signal can obtain the corresponding information of the current powder thin layer.
When the preheating scanning of the thin powder layer by the electron beam is finished once, the image shooting device can shoot and acquire a visible light image and an infrared image, specifically, the image shooting device can be a camera or a camera, in this embodiment, the camera is selected, and the camera can acquire the visible light image and the infrared image in a mode of replacing an optical filter. In this embodiment, the morphology information of the current powder thin layer can be obtained through the visible light image, and the heat distribution information of the current powder thin layer can be obtained through the infrared image.
In the additive manufacturing process, the embodiment can also generate various signals such as electron-hole pairs, lattice vibration (phonon), electron oscillation (plasma) and the like, and the signals can be used for imaging by an image shooting device or an electronic imaging device for detecting forming defects.
In the melting stage, the electron beam melts the thin powder layer, and the electronic imaging device collects the electronic signals to obtain the electronic imaging image corresponding to the electronic signals. When the melting is completed, the electronic imaging device is finished to acquire the visible light image and the infrared image, and the image shooting device starts shooting.
In this embodiment, the acquisition of the visible light image, the infrared image, and the electronic imaging image may be performed at other stages to obtain the forming information of the powder thin layer at other stages.
S20, comparing the visible light image and/or the infrared image with the electronic imaging image singly or after fusion with the standard image, and determining that defects exist in the preheating and/or melting stage when differences exist.
Namely: after the visible light image, the infrared light image and the electronic imaging image are obtained in step S10, the visible light image, the infrared light image and the electronic imaging image may be compared with corresponding standard images, wherein the standard images corresponding to the visible light image and the infrared light image are standard interface shape images generated by slice data of the three-dimensional object model, and the standard images corresponding to the electronic imaging image are energy distribution images and component distribution images obtained by numerical simulation software.
At least two of the visible light image, the infrared image and the electronic imaging image can be fused to form a fused imaging image, the fused imaging image is compared with a standard image corresponding to the fused imaging image, and the standard image is an image formed by fusing a standard interface shape image, an energy distribution image and a component distribution image.
And comparing at least one of the visible light image, the infrared image, the electronic imaging image and the at least two fused imaging images with the standard image corresponding to the at least two fused imaging images, and judging whether defects exist in the preheating stage or the melting stage. Specifically, if there is a difference between the visible light image, the infrared image, the electronic imaging image, and at least two fused imaging images and the standard image corresponding thereto at the time of comparison, it means that there is a defect in the preheating stage or the melting stage.
In this embodiment, the visible light image, the infrared image, the electronic imaging image, and the fused imaging image of at least two of the visible light image, the infrared image, and the electronic imaging image may be compared with the standard images corresponding to the visible light image, the infrared image, and the fused imaging image, respectively, and then the defect in the preheating stage or the melting stage may be accurately determined according to the differences occurring in the multiple contrasts. For example, the appearance difference exists after the visible light image is compared with the standard image corresponding to the visible light image, and the appearance difference also exists after the electronic imaging image is compared with the standard image corresponding to the electronic imaging image, so that the appearance defect can be determined to be necessarily existing in the preheating stage or the melting stage.
It should be noted that when the above-described difference exceeds the set difference, it is indicated that there is a defect in the preheating stage or the melting stage. When the difference does not exceed the set difference, it is indicated that there is no defect in the preheating stage or the melting stage.
The types of defects that typically occur during additive manufacturing include, but are not limited to, the following: uneven spreading of the thin powder layer or lack of powder, concave and convex caused by shape fluctuation after the thin powder layer is melted, change of the shape of a melted section caused by expansion or deficiency of a melted area, material ablation caused by local overheating or too low temperature, unmelted powder, material composition change and the like. The reasons for the defects are generally but not limited to: spreading of the powder material, nature of the powder particles, powder composition, power of the electron beam, beam current size, scanning speed, beam spot shape size, etc.
In this step, the acquisition of the visible light image, the infrared image and the electronic imaging image is not fixed in a certain step, but can be adjusted according to the requirement, for example, if only the outline defect is checked, a detection process can be added after the outline of the thin powder layer of the current layer is melted and before the internal area of the outline is melted; if the powder laying does not need to be inspected, the process of detecting the powder laying defect and the like can be omitted.
And S30, when defects exist in the preheating and/or melting stage, determining the type of the defects and the severity of the defects, and judging whether additive manufacturing can be continued or not according to the type of the defects and/or the severity of the defects.
When it is determined that a defect exists in the preheating stage or the melting stage, the specific type and severity of the defect need to be determined, and the type of the defect can be obtained through forming information obtained through a visible light image, an infrared ray image and an electronic imaging image, wherein some types of the defect influence the whole additive manufacturing process, and therefore the additive manufacturing needs to be stopped. While some types of defects do not affect the overall additive manufacturing process, at which point additive manufacturing may continue.
Meanwhile, whether the additive manufacturing can be continued or not can be judged according to the severity of the defects, when the severity of the defects exceeds the preset degree, the additive manufacturing cannot be continued, and when the severity of the defects does not exceed the preset degree, the additive manufacturing can be continued. The preset degree is the maximum defect degree which can continue additive manufacturing and is obtained in multiple additive manufacturing tests.
In this embodiment, it is understood that the type of defect and the severity of the defect may also be combined to determine whether additive manufacturing can continue.
And S40, when the additive manufacturing can be continued, adjusting the technological parameters of the current time or the next time in the preheating and/or melting stage so as to reduce or repair the defects.
In this step S30, the type of defect is obtained, and at the same time, the position of the defect is obtained, and when additive manufacturing can be continued, the process parameters of the current time or the next time in the preheating stage or the melting stage can be adjusted according to the type of defect and the position of the defect, so as to reduce or repair the defect. For example: when the powder is found to be insufficient in paving, the powder conveying amount is correspondingly increased for paving the powder thin layer next time, so that the powder thin layer is uniformly paved; if the defect area at the heat concentration position reduces the corresponding heat input or quickens the scanning speed, reduces the topography fluctuation or component ablation; such as adding heat input to the defective area of insufficient melting to ensure stable formation while reducing or even repairing defects.
In this embodiment, through the steps S10 to S40, defects existing in the additive manufacturing process can be effectively and accurately detected, the defects can be reduced or even repaired, the detection is accurate, false detection or omission is not easy to occur, and the problem of defect detection lag existing in the existing defect detection is avoided.
The following illustrates the above detection process, specifically as follows:
example 1: referring to fig. 2, fig. 2 is a schematic view of the standard image described above, showing a control image of a thin layer of currently unprocessed powder or a visible light image prior to doctoring. Fig. 3 is a fused imaging image obtained after the preheating scanning and after the fusing of the visible light image and the electronic imaging image, as can be seen from fig. 3, due to the uneven laying of the powder thin layer, there is no powder coverage or less powder coverage on the right lower side, two areas can be identified by the visible light image, a part of the powder is thicker, a part of the powder is thinner, but the printed area can not necessarily be identified, the printed area can be identified by the electronic imaging device, the visible light image and the electronic imaging image are fused, a clear powder layer distribution and an image of the printed area can be obtained, then compared with fig. 2, a powder laying defect can be obviously found, then parameter adjustment can be carried out according to the found powder laying defect, and the powder laying defect can be reduced or repaired when the lower powder thin layer is preheated and scanned.
Example 2: in this example, FIG. 4 is a schematic illustration of a fused imaging image after fusion of a visible image and an infrared image, containing topographical and thermal profile information; FIG. 5 is a schematic illustration of a fused imaging image after the fusion of a secondary electron image and a backscattered electron image from an electron imaging image, containing morphology and composition distribution information; fig. 6 is a schematic diagram of a fused imaging image after fusion of a visible light image, an infrared image, and an electronic imaging image, which contains various information such as morphology, heat distribution, and component distribution. Fig. 4 and fig. 5 can be respectively compared with fig. 2, and when the appearance defect B is shown in fig. 4 and the appearance defect B is also shown in fig. 5, the appearance defect of the current powder thin layer can be accurately judged.
Also for example, in fig. 5, where there is a component defect a, and in fig. 4, where the heat distribution is concentrated (darkened areas in the drawing, i.e., at the ends and arc-shaped positions shown in fig. 4), it can be judged that there is a component defect in the thin layer of the powder before. If it can be judged that the position also has the morphology defect, the defect at the position can be confirmed, and the defect is probably caused by morphology fluctuation caused by component ablation due to heat concentration.
The present embodiment can also determine the morphology defect a and the composition defect B directly by comparing fig. 6 with fig. 2.
After the appearance defect A and the component defect B are determined to exist, the powder conveying quantity and the defect area at the heat concentration position can be changed to reduce the corresponding heat input or accelerate the scanning speed so as to reduce or repair the appearance defect A; an increase or decrease in heat is performed in the current layer or the next layer additive manufacturing to reduce or repair the component defect B.
In this embodiment, the visible light image and/or the infrared image obtained multiple times and the electronic imaging image may be compared to determine whether the existing defect is reduced or repaired, and assist in the defect detection determination process.
In this embodiment, in the additive manufacturing process of each thin powder layer, the obtained visible light image, infrared image and electronic imaging image may not adjust the current or next process parameters in the preheating stage or the melting stage, and may perform overall analysis on the manufacturing process of the three-dimensional entity after the whole additive manufacturing process is finished, so as to directly perform process adjustment when the additive manufacturing is performed next time.
The invention also provides an additive manufacturing device, as shown in fig. 7, which comprises a forming chamber 1, a hopper 2, a powder receiving box 3, a powder laying platform 4, a forming cylinder 5, a piston 6, a scraper 7, a radiation generator 8, an image shooting device 9 and an electronic imaging device 10, wherein:
two hoppers 2 are provided in the forming chamber 1, powder material is contained in the hoppers 2, and a powder receiving box 3 for receiving powder in the two hoppers 2 is provided below the two hoppers 2. A powder spreading platform 4 is arranged below the powder receiving box 3, and the powder material in the powder receiving box 3 is conveyed onto the powder spreading platform 4. A forming cylinder 5 is arranged on the powder spreading platform 4, and a piston 6 which can move up and down is arranged in the forming cylinder 5. Above the powder spreading platform 4 a movable scraper 7 is arranged, which scraper 7 has at least a degree of freedom of movement in the horizontal direction, which scraper 7 is capable of scraping the powder material on the powder spreading platform 4 onto the piston 6 of the forming cylinder 5, forming a thin layer of powder.
In this embodiment, the same powder material or different powder materials may be placed in the two hoppers 2, and the powder materials may be mixed by the powder receiving box 3 and then transferred to the powder spreading platform 4.
Inside the forming chamber 1 a radiation generator 8 is arranged which is capable of generating an electron beam, in particular with an acceleration voltage of 60kV and a power of at most 3kW. The forming chamber 1 is maintained at a pressure of 0.001 to 1Pa by a vacuum obtaining apparatus. The powder material can be pure metal or metal alloy, such as titanium alloy, titanium, aluminum alloy, aluminum, titanium aluminum alloy, stainless steel, co-Cr alloy, etc., and the particle size of the powder is 10-150 microns.
Inside or outside the forming chamber 1, there are provided image capturing means 9 and electronic imaging means 10, which image capturing means 9 and electronic imaging means 10 are each connected to a control device (not shown in the figures), which may be a computer, said image capturing means 9 being adapted to obtain visible light images and/or infrared images during the preheating and/or melting phase, and the electronic imaging means 10 being adapted to obtain electronic imaging images during the preheating and/or melting phase.
Specifically, the image capturing device 9 is a camera or a camera connected to the control device, and in this embodiment, a camera is preferable, and the camera can capture a visible light image and an infrared image by replacing the filter.
The electronic imaging device 10 includes an electronic acquisition device (not shown in the figure) and a signal processing device (not shown in the figure) connected to the electronic acquisition device, wherein the electronic acquisition device is connected to a control device, and is configured to acquire an electronic signal generated during the preheating and/or melting stage and send the electronic signal to the signal processing device, and specific electronic signals are already described in the additive manufacturing defect detection method and are not described again. The signal processing device is connected with the control device and is used for receiving and processing the electronic signals sent by the electronic acquisition device, sending the processing results to the control device and forming electronic imaging images by the control device.
In the printing and manufacturing of a three-dimensional object, first, a model of the three-dimensional object is stored in a computer, the model is layered in the computer, and processing information of each layer is obtained. The manufacture of the three-dimensional object takes place in the forming chamber 1, the powder receiving box 3 mixes and transfers the powder material in the two hoppers 2 onto the powder spreading platform 4, the doctor 7 spreads the powder material into layers above the piston 6 of the forming cylinder 5, after which the thin powder layer is preheated and melted by the electron beam generated by the radiation generator 8 until the thin powder layer of the first layer is completely melted; after the first layer is melted, the powder receiving box 3 conveys the powder material onto the powder spreading platform 4 again, the scraper 7 spreads the powder into thin layers above the piston 6 of the forming cylinder 5 to form a second powder thin layer, the electron beam is generated by the ray generator 8 to preheat and melt the powder thin layer until the second powder thin layer is completely melted … …, the circulation is carried out in this way, and a three-dimensional entity is constructed by continuously processing more than two powder thin layers.
In the preheating and melting process, the image shooting device 9 can acquire a visible light image and/or an infrared image, the electronic imaging device 10 can acquire an electronic imaging image, and the visible light image, the infrared image and the electronic imaging image are compared with a standard image after being singly or fused, so that whether defects exist can be judged according to the comparison result, the detection is accurate, the false detection or the omission is not easy to cause, and the problem of defect detection lag existing in the existing defect detection is avoided.
And the technological parameters can be timely adjusted according to the defects, so that the generation of the defects is reduced or the generated defects are repaired, and the yield of the forming process is increased.
It is to be understood that the above examples of the present invention are provided for clarity of illustration only and are not limiting of the embodiments of the present invention. Other variations or modifications of the above teachings will be apparent to those of ordinary skill in the art. It is not necessary here nor is it exhaustive of all embodiments. Any modification, equivalent replacement, improvement, etc. which come within the spirit and principles of the invention are desired to be protected by the following claims.
Claims (10)
1. A method of additive manufacturing defect detection, comprising:
at least in the preheating and/or melting stage, acquiring visible light images and/or infrared images through an image shooting device and acquiring electronic imaging images through an electronic imaging device;
comparing the visible light image and/or the infrared image with the electronic imaging image singly or after fusion with the standard image, and determining that defects exist in the preheating and/or melting stage when differences exist;
in the process of starting preheating scanning of the thin powder layer by the electron beam, the electron beam can perform preheating scanning on the thin powder layer for a plurality of times, and the electronic imaging device can continuously acquire or acquire an electronic signal of the last preheating scanning when the preheating is finished so as to obtain the electronic imaging image; when the preheating scanning of the thin powder layer by the electron beam is finished once, a visible light image and an infrared image can be shot and obtained by an image shooting device; or/and the combination of the two,
in the melting stage, the electron beam melts the powder thin layer, and the electronic imaging device acquires each electronic signal to obtain the electronic imaging image corresponding to each electronic signal, and when the melting is completed, the electronic imaging device finishes acquiring, and at the moment, the image shooting device starts shooting to acquire the visible light image and the infrared image.
2. The additive manufacturing defect detection method of claim 1, further comprising:
determining the type of defect and the severity of the defect when the defect is present in the preheating and/or melting stage;
and judging whether additive manufacturing can be continued or not according to the type of the defect and/or the severity of the defect.
3. Additive manufacturing defect detection method according to claim 2, wherein said determining whether additive manufacturing can continue according to the type of defect and/or the severity of the defect comprises:
when the type of the defect is not suitable for continuing additive manufacturing or the severity of the defect exceeds a preset level, the additive manufacturing cannot be continued;
additive manufacturing can continue when the type of defect can continue and/or the severity of the defect does not exceed a preset level.
4. The additive manufacturing defect detection method of claim 3, further comprising:
while additive manufacturing can continue, the current or next process parameters in the pre-heating and/or melting stage are adjusted to reduce or repair the defect.
5. The additive manufacturing defect detection method of claim 4, further comprising:
and continuously comparing the visible light image and/or the infrared light image obtained for multiple times with the electronic imaging image to judge whether the defect is reduced or repaired.
6. An additive manufacturing defect detection method according to any of claims 1-5, wherein the standard image is: and generating a standard interface shape image through slice data of the three-dimensional object model, or obtaining an energy distribution image and a component distribution image through numerical simulation software, or fusing the standard interface shape image, the energy distribution image and the component distribution image to form a fused imaging image.
7. Additive manufacturing apparatus for implementing the additive manufacturing defect detection method according to any one of claims 1 to 6, characterized by comprising a forming chamber, an image capturing device installed inside or outside the forming chamber, an electronic imaging device installed inside or outside the forming chamber, and a control device connected to the image capturing device and the electronic imaging device, wherein the image capturing device is used for acquiring a visible light image and/or an infrared light image in a preheating and/or a melting stage, and the electronic imaging device is used for acquiring an electronic imaging image in the preheating and/or the melting stage.
8. Additive manufacturing apparatus according to claim 7, wherein the image capturing device is a camera or a video camera connected to the control device.
9. An additive manufacturing apparatus according to claim 8, wherein when the image capturing device is a camera, the camera captures both visible and infrared images by changing filters.
10. An additive manufacturing apparatus according to claim 7, wherein the electronic imaging device comprises an electronic acquisition device and a signal processing device connected to the electronic acquisition device, wherein:
the electronic acquisition device is connected with the control device and is used for acquiring electronic signals generated in the preheating and/or melting stage and sending the electronic signals to the signal processing device;
the signal processing device is connected with the control device and is used for receiving and processing the electronic signals sent by the electronic acquisition device, sending the processing results to the control device and forming electronic imaging images by the control device.
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