US20170028703A1 - Real-time resonant inspection for additive manufacturing - Google Patents
Real-time resonant inspection for additive manufacturing Download PDFInfo
- Publication number
- US20170028703A1 US20170028703A1 US15/302,785 US201515302785A US2017028703A1 US 20170028703 A1 US20170028703 A1 US 20170028703A1 US 201515302785 A US201515302785 A US 201515302785A US 2017028703 A1 US2017028703 A1 US 2017028703A1
- Authority
- US
- United States
- Prior art keywords
- workpiece
- resonant frequency
- additive manufacturing
- completion
- unflawed
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Images
Classifications
-
- 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
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/80—Data acquisition or data processing
- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
-
- B22F3/1055—
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K15/00—Electron-beam welding or cutting
- B23K15/0026—Auxiliary equipment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K15/00—Electron-beam welding or cutting
- B23K15/0046—Welding
- B23K15/0086—Welding welding for purposes other than joining, e.g. built-up welding
-
- 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
- B33Y10/00—Processes of additive manufacturing
-
- 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
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D11/00—Preventing or minimising internal leakage of working-fluid, e.g. between stages
- F01D11/08—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/005—Repairing methods or devices
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/14—Form or construction
- F01D5/147—Construction, i.e. structural features, e.g. of weight-saving hollow blades
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/286—Particular treatment of blades, e.g. to increase durability or resistance against corrosion or erosion
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/288—Protective coatings for blades
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D9/00—Stators
- F01D9/02—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
- G01H13/00—Measuring resonant frequency
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
- G01N29/043—Analysing solids in the interior, e.g. by shear waves
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
- G01N29/12—Analysing solids by measuring frequency or resonance of acoustic waves
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
- G01N29/4409—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison
- G01N29/4427—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison with stored values, e.g. threshold values
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
- G01N29/4409—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison
- G01N29/4436—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison with a reference signal
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/50—Means for feeding of material, e.g. heads
- B22F12/57—Metering means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/90—Means for process control, e.g. cameras or sensors
-
- B22F2003/1057—
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2220/00—Application
- F05D2220/30—Application in turbines
- F05D2220/32—Application in turbines in gas turbines
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/22—Manufacture essentially without removing material by sintering
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
- F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
- F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
- F05D2230/234—Laser welding
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/30—Manufacture with deposition of material
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/30—Manufacture with deposition of material
- F05D2230/31—Layer deposition
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2260/00—Function
- F05D2260/96—Preventing, counteracting or reducing vibration or noise
-
- 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
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the present invention relates generally to additive manufacturing, and more particularly the methods and systems for fabricating gas turbine engine workpieces via additive manufacturing.
- Gas turbine engines are internal combustion engines with upstream compressors and downstream turbines fluidly connected through a combustor. Gas turbines operate according to the Brayton cycle, extracting energy from high-pressure, high-temperature airflow downstream of the combustor, where fuel is injected into pressurized airflow from the compressor, and ignited. Many gas turbine engine components guide airflow, either as a working fluid of the engine, or for cooling. Blades and vanes, for instance, are airfoil components with smooth outer surfaces configured to guide working fluid for compression (in a compressor) or energy extraction (in a turbine).
- Additive manufacturing is increasingly used to fabricate gas turbine engine workpieces such as blades, vanes, and air seals. Tolerances for these parts are often very fine. Defective parts that fail to meet design specifications can sometimes be reworked or repaired, but must often be discarded, at significant cost.
- the present invention relates to a method of additive manufacturing.
- the method comprises determining a first resonant frequency of an unflawed reference workpiece at a first partial stage of completion, fabricating a production workpiece to the first partial stage of completion via additive manufacture, sensing a second resonant frequency of the production workpiece in-situ at the first partial stage of completion, during the fabrication, analyzing the workpiece for flaws based on comparison of the first and second resonant frequencies, and providing an output indicative of production workpiece condition, based on the analysis
- the present invention relates to an additive manufacturing system comprising an additive manufacturing tool, a sensor, and a controller.
- the additive manufacturing tool is disposed to construct a workpiece via iterative layer deposition.
- the sensor is disposed to determine a resonant frequency of the workpiece in-situ at the additive manufacturing tool, during fabrication.
- the controller is configured to terminate manufacture of the workpiece if the resonant frequency differs substantially from a reference frequency.
- FIG. 1 is a schematic block diagram of an embodiment of an additive manufacturing system.
- FIG. 2 is a method flowchart of an embodiment of a method of additive manufacturing using the system of FIG. 1 .
- the present invention allows additive manufacturing workpieces to be inspected in-situ during production, in real time. In this way, flawed workpieces can be identified and discarded or set aside for repair immediately, at a partial stage of production. Thus, the present invention avoids devoting additional material and production time to defective workpieces.
- FIG. 1 is a schematic diagram of additive manufacturing system 10 , which comprises additive manufacturing tool 12 and controller 14 .
- Additive manufacturing tool 12 comprises pulverant material reservoir 16 , pulverant dispensers 18 , laser guide 20 , platform 22 for workpiece 24 , and sensor 26 .
- Controller 14 comprises reference database 28 and processor 30 .
- Workpiece 24 is compared to reference workpiece 24 ′, as described in greater detail below.
- Additive manufacturing system 10 is a system for the fabrication of workpieces such as gas turbine engine blades, vanes, and air seals via iterative deposition of layers of pulverant material.
- additive manufacturing tool 12 is a direct metal laser sintering (DMLS) system.
- DMLS direct metal laser sintering
- Pulverant material reservoir 16 of additive manufacturing tool 12 can be any container suitable for holding pulverant material suitable for use in additive manufacturing, such as fine powders of conductors or insulators.
- this pulverant material can be superalloy powder, or ceramics powder.
- Pulverant material dispensers 18 can be opened or closed to selectively restrict flow of pulverant material to workpiece 24 on platform 22 .
- Laser guide 20 is a laser emitter or focusing element that directs a laser to soften, melt or sinter pulverant material deposited by pulverant material dispensers 18 .
- Additive manufacturing tool 12 builds workpiece 24 layer-by-layer by iteratively depositing and sintering pulverant atop platform 22 .
- Platform 22 can, for instance, be a mobile platform configured to position a working region of workpiece 24 beneath laser guide 20 .
- laser guide 20 and/or additive manufacturing tool 12 as a whole can be a movable or directable device capable of adjusting this working region relative to a stationary embodiment of platform 22 .
- additive manufacturing tool 12 is depicted as a DMLS system, a variety of other additive manufacturing tools can alternatively be used, including laser additive manufacturing (LAM) tools (e.g. laser engineered net shaping (LENS), laser powder deposition (LPD), or selective laser sintering (SLS) apparatus) or electron beam machining tools (e.g. electron beam melting (EBM) or electron beam wire (EBW) apparatus).
- LAM laser additive manufacturing
- LENS laser engineered net shaping
- LLD laser powder deposition
- SLS selective laser sintering
- electron beam machining tools e.g. electron beam melting (EBM) or electron beam wire (EBW) apparatus
- additive manufacturing tool 12 can incorporate a plurality of additive manufacturing tools 22 (of similar or differing configurations) that operate sequentially or in parallel. All embodiments of additive manufacturing system 10 build workpiece 24 layer-by-layer atop additive manufacturing platform 22 .
- Controller 14 is a logic-capable device that manages additive manufacturing of workpiece 24 , e.g. by controlling the movement platform 22 or pulverant dispensers 18 , directing laser guide 20 , and metering pulverant material supplied from pulverant material reservoir 16 .
- Controller 14 can, for instance, be a microprocessor incorporated into additive manufacturing tool 12 , or a separate user workstation or control computer situated elsewhere.
- Controller 14 can, for instance, be programmed with a part design describing workpiece 24 in three dimensions. Alternatively, controller 14 can specify the steps to fabricating workpiece 24 and machining workpiece 24 without including a full design of the finished gas turbine component.
- controller 14 is depicted as a single unitary component, some embodiments of additive manufacturing system 10 can use more than one controller 14 .
- some embodiments of additive manufacturing system 10 can include a plurality of (e.g. parallel) additive manufacturing tools 12 , each with associated controller 14 .
- Controller 14 receives frequency signals from sensor 26 reflecting the resonant frequency of workpiece 24 at increasing stages of its fabrication.
- Sensor 26 is a resonant frequency sensor directly or indirectly abutting and directly or indirectly physically contacting workpiece 24 .
- Sensor 26 can, for example, be an active sensor disposed to “ping” workpiece 24 and sense resonant frequency from resulting vibration.
- Sensor 26 can sense resonant frequency periodically, or in response to signal requests from controller 14 .
- Sensor 14 provides controller 14 with real-time values of the resonant frequency of workpiece 24 , during fabrication.
- controller 14 comprises reference database 28 and processor 30 .
- Reference database 28 stores an archive of reference resonant frequencies corresponding to optimal (i.e.
- unflawed states of reference workpiece 24 ′ at the various stages of its fabrication.
- Processor 30 analyzes workpiece 24 for flaws in real time during its fabrication by comparing sensed resonant frequencies from sensor 26 to corresponding reference frequencies from reference database 28 . If corresponding sensed and reference frequencies at a given stage of completion differ by more than a threshold value (e.g. 10%), processor 30 provides an output indicating that workpiece is flawed. Controller 14 can then command that (flawed) workpiece 24 be discarded or set aside for repair, so as to not waste further material and assembly time on an unusable part.
- a threshold value e.g. 10%
- FIG. 2 is a method flowchart illustrating method 100 , one possible embodiment of a method of operation for additive manufacturing system 10 .
- Method 100 is a real-time resonant frequency inspection method whereby the resonant frequency of workpiece 24 is checked against reference frequency values corresponding an unflawed workpiece at successive stages of fabrication, as described above with respect to FIG. 1 .
- reference database 28 is populated with reference frequencies.
- These reference frequencies can be determined in a variety of ways.
- reference frequencies corresponding to each stage of completion of workpiece 24 are determined by fabricating a physical reference workpiece 24 ′ to that stage of completion, independently verifying that reference workpiece 24 ′ is unflawed (e.g. by physical testing, inspection, or imaging), and sensing its reference frequency.
- reference frequencies corresponding to each stage of completion of workpiece 24 are determined by fabricating a complete physical reference workpiece 24 ′, independently verifying that reference workpiece 24 ′ is unflawed, and successively machining away material from reference workpiece 24 ′ until the reference workpiece 24 ′ is reduced to each partial stage of completion.
- reference frequencies corresponding to each stage of completion of workpiece 24 are determined by computing resonant frequencies of a simulated reference workpiece 24 ′, e.g. using a computer model. For greater precision, any of these methods can be repeated to produce a range or average value of optimal or acceptable workpiece resonant frequencies, at each stage of completion. In some cases, two or more methods can be used to independently produce reference frequencies that are compared to ensure reliability.
- additive manufacture tool 12 can begin fabrication of workpiece 24 .
- Additive manufacture tool 12 fabricates workpiece 24 up to a reference point corresponding to a stage of completion for which reference database 28 holds a corresponding reference frequency.
- This reference point can, for example, be a step in a digital map describing the fabrication process of workpiece 24 , a number of layers deposited, or a thickness or size of workpiece 24 fabricated thus-far or another suitable step, parameter, or characteristic.
- Sensor 26 senses a resonant frequency of workpiece 24 at this stage of completion, and transmits the sensed frequency to controller 14 .
- Step S 3 Step S 3 ).
- Processor 30 compares the sensed frequency to a corresponding reference frequency stored in reference database 28 . (Step S 4 ). If the sensed frequency fails to match the corresponding reference frequency, controller 14 provides an output indicating that workpiece 24 is flawed, and instructs additive manufacturing tool 12 to terminate fabrication and discard or set aside the flawed workpiece. (Step S 5 ). If the sensed frequency falls within an acceptable range of the corresponding reference frequency (e.g. ⁇ 10%), processor 30 determines whether fabrication of workpiece 24 is complete. (Step S 6 ). If not, fabrication continues from Step S 2 . When workpiece 24 is complete, method 100 terminates, and additive manufacturing system 10 releases complete, unflawed workpiece 24 . (Step S 7 ). When fabrication terminates due to completion or flaw detection, additive manufacturing system 10 can reset, beginning fabrication of a new workpiece (Step S 2 ). Step S 1 need not be repeated for each new workpiece.
- Additive manufacturing system 10 and method 100 allow for waste to be reduced or minimized while fabricating workpiece 24 . Rather than spending additional manufacturing time depositing further layers of pulverant material on a flawed workpiece, method 100 allows additive manufacturing system 10 to recognize flaws and prematurely terminate production of the flawed workpiece, thereby preventing waste. Additive manufacturing system 10 and method 100 also serve as additional quality control checks, ensuring that workpieces 24 meet design specifications.
- a method of additive manufacturing comprises: determining a first resonant frequency of an unflawed reference workpiece at a first partial stage of completion; fabricating a production workpiece to the first partial stage of completion via additive manufacture; sensing a second resonant frequency of the production workpiece in-situ at the first partial stage of completion, during the fabricating; analyzing the workpiece for flaws based on comparison of the first and second resonant frequencies; and providing an output indicative of production workpiece condition, based on the analysis.
- the method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
- a further embodiment of the foregoing method further comprising prematurely terminating fabrication of the production in response to substantial deviation of the second resonant frequency from the first resonant frequency.
- determining the first resonant frequency comprises sensing the resonant frequency of a workpiece independently verified as unflawed, at the first partial stage of completion
- determining the first resonant frequency comprises: completely fabricating the unflawed reference workpiece; machining away material from the unflawed reference workpiece until the unflawed reference workpiece is reduced to the first partial stage of completion; and acoustically sensing a resonant frequency of the unflawed reference workpiece.
- determining the first resonant frequency comprises simulating the unflawed reference workpiece, and computing a resonant frequency of the simulated unflawed reference workpiece.
- a further embodiment of the foregoing method further comprising: determining at least a third resonant frequency of the unflawed reference workpiece at a second partial stage of completion distinct from the first stage of completion; sensing at least a fourth resonant frequency of the production workpiece in-situ at the second partial stage of completion; and analyzing the workpiece for flaws based on comparison of at least the third and fourth resonant frequencies.
- An additive manufacturing system comprises: an additive manufacturing tool disposed to construct a workpiece via iterative layer deposition; a sensor disposed to determine a resonant frequency of the workpiece in-situ at the additive manufacturing tool, during fabrication; and a controller configured to terminate manufacture of the workpiece if the resonant frequency differs substantially from a reference frequency.
- the additive manufacturing system of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
- a further embodiment of the foregoing additive manufacturing system wherein the additive manufacturing tool comprises an electron beam machining apparatus.
- a further embodiment of the foregoing additive manufacturing system wherein the additive manufacturing tool comprises a direct metal laser sintering apparatus.
- a further embodiment of the foregoing additive manufacturing system wherein the sensor is disposed to periodically determine the resonant frequency at multiple stages of completion of the workpiece, and the controller is configured to terminate manufacture of the workpiece if at any time the resonant frequency differs substantially from a corresponding reference frequency.
- controller comprises a processor and a database containing a plurality of reference frequencies.
- a further embodiment of the foregoing additive manufacturing system wherein the sensor is an active sensor disposed to both induce and sense vibration in the workpiece.
Abstract
A method of additive manufacturing comprises determining a first resonant frequency of an unflawed reference workpiece at a first partial stage of completion, fabricating a production workpiece to the first partial stage of completion via additive manufacture, sensing a second resonant frequency of the production workpiece in-situ at the first partial stage of completion, during the fabrication, analyzing the workpiece for flaws based on comparison of the first and second resonant frequencies, and providing an output indicative of production workpiece condition, based on the analysis. An additive manufacturing system comprises an additive manufacturing tool, a sensor, and a controller. The additive manufacturing tool is disposed to construct a workpiece via iterative layer deposition. The sensor is disposed to determine a resonant frequency of the workpiece in-situ at the additive manufacturing tool, during fabrication. The controller is configured to terminate manufacture of the workpiece if the resonant frequency differs substantially from a reference frequency.
Description
- The present invention relates generally to additive manufacturing, and more particularly the methods and systems for fabricating gas turbine engine workpieces via additive manufacturing.
- Gas turbine engines are internal combustion engines with upstream compressors and downstream turbines fluidly connected through a combustor. Gas turbines operate according to the Brayton cycle, extracting energy from high-pressure, high-temperature airflow downstream of the combustor, where fuel is injected into pressurized airflow from the compressor, and ignited. Many gas turbine engine components guide airflow, either as a working fluid of the engine, or for cooling. Blades and vanes, for instance, are airfoil components with smooth outer surfaces configured to guide working fluid for compression (in a compressor) or energy extraction (in a turbine).
- Additive manufacturing is increasingly used to fabricate gas turbine engine workpieces such as blades, vanes, and air seals. Tolerances for these parts are often very fine. Defective parts that fail to meet design specifications can sometimes be reworked or repaired, but must often be discarded, at significant cost.
- In one embodiment, the present invention relates to a method of additive manufacturing. The method comprises determining a first resonant frequency of an unflawed reference workpiece at a first partial stage of completion, fabricating a production workpiece to the first partial stage of completion via additive manufacture, sensing a second resonant frequency of the production workpiece in-situ at the first partial stage of completion, during the fabrication, analyzing the workpiece for flaws based on comparison of the first and second resonant frequencies, and providing an output indicative of production workpiece condition, based on the analysis
- In another embodiment, the present invention relates to an additive manufacturing system comprising an additive manufacturing tool, a sensor, and a controller. The additive manufacturing tool is disposed to construct a workpiece via iterative layer deposition. The sensor is disposed to determine a resonant frequency of the workpiece in-situ at the additive manufacturing tool, during fabrication. The controller is configured to terminate manufacture of the workpiece if the resonant frequency differs substantially from a reference frequency.
-
FIG. 1 is a schematic block diagram of an embodiment of an additive manufacturing system. -
FIG. 2 is a method flowchart of an embodiment of a method of additive manufacturing using the system ofFIG. 1 . - While the above-identified figures set forth embodiments of the present disclosure, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the invention. The figures may not be drawn to scale, and applications and embodiments of the present invention may include features and components not specifically shown in the drawings.
- In a variety of applications including gas turbine engine part additive manufacturing, workpieces can develop defects during fabrication. To limit waste, the present invention allows additive manufacturing workpieces to be inspected in-situ during production, in real time. In this way, flawed workpieces can be identified and discarded or set aside for repair immediately, at a partial stage of production. Thus, the present invention avoids devoting additional material and production time to defective workpieces.
-
FIG. 1 is a schematic diagram ofadditive manufacturing system 10, which comprisesadditive manufacturing tool 12 andcontroller 14.Additive manufacturing tool 12 comprisespulverant material reservoir 16,pulverant dispensers 18,laser guide 20,platform 22 forworkpiece 24, andsensor 26.Controller 14 comprisesreference database 28 andprocessor 30.Workpiece 24 is compared toreference workpiece 24′, as described in greater detail below. -
Additive manufacturing system 10 is a system for the fabrication of workpieces such as gas turbine engine blades, vanes, and air seals via iterative deposition of layers of pulverant material. In the depicted embodiment,additive manufacturing tool 12 is a direct metal laser sintering (DMLS) system. Persons skilled in the art, however, will recognize that the present system and method can utilize alternatively use other additive manufacturing techniques. -
Pulverant material reservoir 16 ofadditive manufacturing tool 12 can be any container suitable for holding pulverant material suitable for use in additive manufacturing, such as fine powders of conductors or insulators. For example, this pulverant material can be superalloy powder, or ceramics powder.Pulverant material dispensers 18 can be opened or closed to selectively restrict flow of pulverant material toworkpiece 24 onplatform 22.Laser guide 20 is a laser emitter or focusing element that directs a laser to soften, melt or sinter pulverant material deposited bypulverant material dispensers 18.Additive manufacturing tool 12 buildsworkpiece 24 layer-by-layer by iteratively depositing and sintering pulverant atopplatform 22.Platform 22 can, for instance, be a mobile platform configured to position a working region ofworkpiece 24 beneathlaser guide 20. Alternatively,laser guide 20 and/oradditive manufacturing tool 12 as a whole can be a movable or directable device capable of adjusting this working region relative to a stationary embodiment ofplatform 22. - Although
additive manufacturing tool 12 is depicted as a DMLS system, a variety of other additive manufacturing tools can alternatively be used, including laser additive manufacturing (LAM) tools (e.g. laser engineered net shaping (LENS), laser powder deposition (LPD), or selective laser sintering (SLS) apparatus) or electron beam machining tools (e.g. electron beam melting (EBM) or electron beam wire (EBW) apparatus). In some embodiments,additive manufacturing tool 12 can incorporate a plurality of additive manufacturing tools 22 (of similar or differing configurations) that operate sequentially or in parallel. All embodiments ofadditive manufacturing system 10 buildworkpiece 24 layer-by-layer atopadditive manufacturing platform 22. -
Controller 14 is a logic-capable device that manages additive manufacturing ofworkpiece 24, e.g. by controlling themovement platform 22 orpulverant dispensers 18, directinglaser guide 20, and metering pulverant material supplied frompulverant material reservoir 16.Controller 14 can, for instance, be a microprocessor incorporated intoadditive manufacturing tool 12, or a separate user workstation or control computer situated elsewhere.Controller 14 can, for instance, be programmed with a partdesign describing workpiece 24 in three dimensions. Alternatively,controller 14 can specify the steps to fabricatingworkpiece 24 and machiningworkpiece 24 without including a full design of the finished gas turbine component. Althoughcontroller 14 is depicted as a single unitary component, some embodiments ofadditive manufacturing system 10 can use more than onecontroller 14. In particular, some embodiments ofadditive manufacturing system 10 can include a plurality of (e.g. parallel)additive manufacturing tools 12, each withassociated controller 14. -
Controller 14 receives frequency signals fromsensor 26 reflecting the resonant frequency ofworkpiece 24 at increasing stages of its fabrication.Sensor 26 is a resonant frequency sensor directly or indirectly abutting and directly or indirectly physically contactingworkpiece 24.Sensor 26 can, for example, be an active sensor disposed to “ping”workpiece 24 and sense resonant frequency from resulting vibration.Sensor 26 can sense resonant frequency periodically, or in response to signal requests fromcontroller 14.Sensor 14 providescontroller 14 with real-time values of the resonant frequency ofworkpiece 24, during fabrication. As described in greater detail below with respect tomethod 100 ofFIG. 2 ,controller 14 comprisesreference database 28 andprocessor 30.Reference database 28 stores an archive of reference resonant frequencies corresponding to optimal (i.e. unflawed) states ofreference workpiece 24′, at the various stages of its fabrication.Processor 30 analyzesworkpiece 24 for flaws in real time during its fabrication by comparing sensed resonant frequencies fromsensor 26 to corresponding reference frequencies fromreference database 28. If corresponding sensed and reference frequencies at a given stage of completion differ by more than a threshold value (e.g. 10%),processor 30 provides an output indicating that workpiece is flawed.Controller 14 can then command that (flawed)workpiece 24 be discarded or set aside for repair, so as to not waste further material and assembly time on an unusable part. -
FIG. 2 is a method flowchartillustrating method 100, one possible embodiment of a method of operation foradditive manufacturing system 10.Method 100 is a real-time resonant frequency inspection method whereby the resonant frequency ofworkpiece 24 is checked against reference frequency values corresponding an unflawed workpiece at successive stages of fabrication, as described above with respect toFIG. 1 . - First,
reference database 28 is populated with reference frequencies. (Step S1). These reference frequencies can be determined in a variety of ways. In one embodiment, reference frequencies corresponding to each stage of completion ofworkpiece 24 are determined by fabricating aphysical reference workpiece 24′ to that stage of completion, independently verifying thatreference workpiece 24′ is unflawed (e.g. by physical testing, inspection, or imaging), and sensing its reference frequency. In another embodiment, reference frequencies corresponding to each stage of completion ofworkpiece 24 are determined by fabricating a completephysical reference workpiece 24′, independently verifying thatreference workpiece 24′ is unflawed, and successively machining away material from reference workpiece 24′ until thereference workpiece 24′ is reduced to each partial stage of completion. At each stage of completion, the resonant frequency ofreference workpiece 24′ is sensed to populatereference database 28. In yet another embodiment, reference frequencies corresponding to each stage of completion ofworkpiece 24 are determined by computing resonant frequencies of asimulated reference workpiece 24′, e.g. using a computer model. For greater precision, any of these methods can be repeated to produce a range or average value of optimal or acceptable workpiece resonant frequencies, at each stage of completion. In some cases, two or more methods can be used to independently produce reference frequencies that are compared to ensure reliability. - Once
reference database 28 has been populated with reference frequencies using any or all of the methods described above,additive manufacture tool 12 can begin fabrication ofworkpiece 24.Additive manufacture tool 12 fabricatesworkpiece 24 up to a reference point corresponding to a stage of completion for whichreference database 28 holds a corresponding reference frequency. (Step S2). This reference point can, for example, be a step in a digital map describing the fabrication process ofworkpiece 24, a number of layers deposited, or a thickness or size ofworkpiece 24 fabricated thus-far or another suitable step, parameter, or characteristic.Sensor 26 senses a resonant frequency ofworkpiece 24 at this stage of completion, and transmits the sensed frequency tocontroller 14. (Step S3).Processor 30 compares the sensed frequency to a corresponding reference frequency stored inreference database 28. (Step S4). If the sensed frequency fails to match the corresponding reference frequency,controller 14 provides an output indicating thatworkpiece 24 is flawed, and instructsadditive manufacturing tool 12 to terminate fabrication and discard or set aside the flawed workpiece. (Step S5). If the sensed frequency falls within an acceptable range of the corresponding reference frequency (e.g. ±10%),processor 30 determines whether fabrication ofworkpiece 24 is complete. (Step S6). If not, fabrication continues from Step S2. When workpiece 24 is complete,method 100 terminates, andadditive manufacturing system 10 releases complete,unflawed workpiece 24. (Step S7). When fabrication terminates due to completion or flaw detection,additive manufacturing system 10 can reset, beginning fabrication of a new workpiece (Step S2). Step S1 need not be repeated for each new workpiece. -
Additive manufacturing system 10 andmethod 100 allow for waste to be reduced or minimized while fabricatingworkpiece 24. Rather than spending additional manufacturing time depositing further layers of pulverant material on a flawed workpiece,method 100 allowsadditive manufacturing system 10 to recognize flaws and prematurely terminate production of the flawed workpiece, thereby preventing waste.Additive manufacturing system 10 andmethod 100 also serve as additional quality control checks, ensuring thatworkpieces 24 meet design specifications. - The following are non-exclusive descriptions of possible embodiments of the present invention.
- A method of additive manufacturing comprises: determining a first resonant frequency of an unflawed reference workpiece at a first partial stage of completion; fabricating a production workpiece to the first partial stage of completion via additive manufacture; sensing a second resonant frequency of the production workpiece in-situ at the first partial stage of completion, during the fabricating; analyzing the workpiece for flaws based on comparison of the first and second resonant frequencies; and providing an output indicative of production workpiece condition, based on the analysis.
- The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
- A further embodiment of the foregoing method, further comprising prematurely terminating fabrication of the production in response to substantial deviation of the second resonant frequency from the first resonant frequency.
- A further embodiment of the foregoing method, wherein the first resonant frequency differs substantially from the second resonant frequency if the first and second resonant frequencies differ by 10% or more.
- A further embodiment of the foregoing method, wherein determining the first resonant frequency comprises sensing the resonant frequency of a workpiece independently verified as unflawed, at the first partial stage of completion
- A further embodiment of the foregoing method, wherein determining the first resonant frequency comprises: completely fabricating the unflawed reference workpiece; machining away material from the unflawed reference workpiece until the unflawed reference workpiece is reduced to the first partial stage of completion; and acoustically sensing a resonant frequency of the unflawed reference workpiece.
- A further embodiment of the foregoing method, wherein determining the first resonant frequency comprises simulating the unflawed reference workpiece, and computing a resonant frequency of the simulated unflawed reference workpiece.
- A further embodiment of the foregoing method, further comprising: determining at least a third resonant frequency of the unflawed reference workpiece at a second partial stage of completion distinct from the first stage of completion; sensing at least a fourth resonant frequency of the production workpiece in-situ at the second partial stage of completion; and analyzing the workpiece for flaws based on comparison of at least the third and fourth resonant frequencies.
- An additive manufacturing system comprises: an additive manufacturing tool disposed to construct a workpiece via iterative layer deposition; a sensor disposed to determine a resonant frequency of the workpiece in-situ at the additive manufacturing tool, during fabrication; and a controller configured to terminate manufacture of the workpiece if the resonant frequency differs substantially from a reference frequency.
- The additive manufacturing system of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
- A further embodiment of the foregoing additive manufacturing system, wherein the additive manufacturing tool comprises an electron beam machining apparatus.
- A further embodiment of the foregoing additive manufacturing system, wherein the additive manufacturing tool comprises a direct metal laser sintering apparatus.
- A further embodiment of the foregoing additive manufacturing system, wherein the sensor is disposed to periodically determine the resonant frequency at multiple stages of completion of the workpiece, and the controller is configured to terminate manufacture of the workpiece if at any time the resonant frequency differs substantially from a corresponding reference frequency.
- A further embodiment of the foregoing additive manufacturing system, wherein the controller comprises a processor and a database containing a plurality of reference frequencies.
- A further embodiment of the foregoing additive manufacturing system, wherein the sensor is an active sensor disposed to both induce and sense vibration in the workpiece.
- While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims (13)
1. A method of additive manufacturing comprises:
determining a first resonant frequency of an unflawed reference workpiece at a first partial stage of completion;
fabricating a production workpiece to the first partial stage of completion via additive manufacture;
sensing a second resonant frequency of the production workpiece in-situ at the first partial stage of completion, during the fabricating;
analyzing the workpiece for flaws based on comparison of the first and second resonant frequencies; and
providing an output indicative of production workpiece condition, based on the analysis.
2. The method of claim 1 , further comprising:
prematurely terminating fabrication of the production in response to substantial deviation of the second resonant frequency from the first resonant frequency.
3. The method of claim 2 , wherein the first resonant frequency differs substantially from the second resonant frequency if the first and second resonant frequencies differ by 10% or more.
4. The method of claim 1 , wherein determining the first resonant frequency comprises sensing the resonant frequency of a workpiece independently verified as unflawed, at the first partial stage of completion
5. The method of claim 1 , wherein determining the first resonant frequency comprises:
completely fabricating the unflawed reference workpiece;
machining away material from the unflawed reference workpiece until the unflawed reference workpiece is reduced to the first partial stage of completion; and
acoustically sensing a resonant frequency of the unflawed reference workpiece.
6. The method of claim 1 , wherein determining the first resonant frequency comprises simulating the unflawed reference workpiece, and computing a resonant frequency of the simulated unflawed reference workpiece.
7. The method of claim 1 , further comprising:
determining at least a third resonant frequency of the unflawed reference workpiece at a second partial stage of completion distinct from the first stage of completion;
sensing at least a fourth resonant frequency of the production workpiece in-situ at the second partial stage of completion; and
analyzing the workpiece for flaws based on comparison of at least the third and fourth resonant frequencies.
8. An additive manufacturing system comprises:
an additive manufacturing tool disposed to construct a workpiece via iterative layer deposition;
a sensor disposed to determine a resonant frequency of the workpiece in-situ at the additive manufacturing tool, during fabrication; and
a controller configured to terminate manufacture of the workpiece if the resonant frequency differs substantially from a reference frequency.
9. The additive manufacturing system of claim 8 , wherein the additive manufacturing tool comprises an electron beam machining apparatus
10. The additive manufacturing system of claim 8 , wherein the additive manufacturing tool comprises a direct metal laser sintering apparatus.
11. The additive manufacturing system of claim 8 , wherein the sensor is disposed to periodically determine the resonant frequency at multiple stages of completion of the workpiece, and the controller is configured to terminate manufacture of the workpiece if at any time the resonant frequency differs substantially from a corresponding reference frequency.
12. The additive manufacturing system of claim 8 , wherein the controller comprises a processor and a database containing a plurality of reference frequencies.
13. The additive manufacturing system of claim 8 , wherein the sensor is an active sensor disposed to both induce and sense vibration in the workpiece.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/302,785 US20170028703A1 (en) | 2014-04-10 | 2015-04-08 | Real-time resonant inspection for additive manufacturing |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201461977801P | 2014-04-10 | 2014-04-10 | |
PCT/US2015/024863 WO2015157381A1 (en) | 2014-04-10 | 2015-04-08 | Real-time resonant inspection for additive manufacturing |
US15/302,785 US20170028703A1 (en) | 2014-04-10 | 2015-04-08 | Real-time resonant inspection for additive manufacturing |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2015/024863 A-371-Of-International WO2015157381A1 (en) | 2014-04-10 | 2015-04-08 | Real-time resonant inspection for additive manufacturing |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/703,467 Division US11020954B2 (en) | 2014-04-10 | 2019-12-04 | Method of resonant inspection for additive manufacturing |
Publications (1)
Publication Number | Publication Date |
---|---|
US20170028703A1 true US20170028703A1 (en) | 2017-02-02 |
Family
ID=54288359
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/302,785 Abandoned US20170028703A1 (en) | 2014-04-10 | 2015-04-08 | Real-time resonant inspection for additive manufacturing |
US16/703,467 Active US11020954B2 (en) | 2014-04-10 | 2019-12-04 | Method of resonant inspection for additive manufacturing |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/703,467 Active US11020954B2 (en) | 2014-04-10 | 2019-12-04 | Method of resonant inspection for additive manufacturing |
Country Status (3)
Country | Link |
---|---|
US (2) | US20170028703A1 (en) |
EP (1) | EP3129772A4 (en) |
WO (1) | WO2015157381A1 (en) |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20190015901A1 (en) * | 2016-01-28 | 2019-01-17 | Siemens Aktiengesellschaft | Method for checking a component to be produced in an additive manner, and device |
US20200223146A1 (en) * | 2017-06-20 | 2020-07-16 | Carl Zeiss Industrielle Messtechnik Gmbh | Method and Device for Additive Manufacturing |
WO2020178551A1 (en) * | 2019-03-06 | 2020-09-10 | Hieta Technologies Limited | Manufacturing apparatus and method |
US10857735B1 (en) * | 2017-04-25 | 2020-12-08 | Hrl Laboratories, Llc | Apparatus and method for additive manufacturing and determining the development of stress during additive manufacturing |
US11052606B2 (en) | 2018-11-27 | 2021-07-06 | Hamilton Sundstrand Corporation | Platform drop sensor |
US11073501B2 (en) * | 2015-11-13 | 2021-07-27 | Honeywell Federal Manufacturing & Technologies, Llc | System and method for inspecting parts using dynamic response function |
US11167375B2 (en) | 2018-08-10 | 2021-11-09 | The Research Foundation For The State University Of New York | Additive manufacturing processes and additively manufactured products |
DE102021200473A1 (en) | 2021-01-20 | 2022-07-21 | Volkswagen Aktiengesellschaft | Method and device for the additive manufacturing of at least one component from a shapeless material |
DE112019002366B4 (en) | 2018-05-08 | 2023-01-05 | Vibrant Corporation | RESONANCE STUDY OF PRODUCTION ITEMS BY REVIEW OF DOCUMENT PRODUCTS |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3187685A1 (en) * | 2015-12-28 | 2017-07-05 | Siemens Aktiengesellschaft | Method for producing a base part of a turbine blade |
FR3120444A1 (en) * | 2021-03-03 | 2022-09-09 | Commissariat A L’Energie Atomique Et Aux Energies Alternatives | Process for detecting cracks in an aluminum alloy part produced by additive manufacturing. |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20110121492A1 (en) * | 2009-11-25 | 2011-05-26 | Eos Gmbh Electro Optical Systems | Method for manufacturing a three-dimensional object |
WO2012097799A2 (en) * | 2011-01-18 | 2012-07-26 | Mtu Aero Engines Gmbh | Process and apparatus for testing the generative production of a component |
US20130088724A1 (en) * | 2011-10-11 | 2013-04-11 | Marc Dubois | Method and apparatus for the inspection of sandwich structures using laser-induced resonant frequencies |
Family Cites Families (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2549312B2 (en) * | 1989-08-15 | 1996-10-30 | セイコー精機株式会社 | Machining state detection device for machine tools |
US5351543A (en) * | 1991-12-27 | 1994-10-04 | The Regents Of The University Of California, Office Of Technology Transfer | Crack detection using resonant ultrasound spectroscopy |
US5425272A (en) * | 1993-11-30 | 1995-06-20 | Quatro Corporation | Relative resonant frequency shifts to detect cracks |
US6553275B1 (en) * | 1999-03-11 | 2003-04-22 | Jyoti Mazumder | In-situ stress monitoring during direct material deposition process |
US6580959B1 (en) * | 1999-03-11 | 2003-06-17 | Precision Optical Manufacturing (Pom) | System and method for remote direct material deposition |
CA2455907A1 (en) | 2004-01-26 | 2005-07-26 | Johnny Michael Knox | Wheel assembly |
US20050173380A1 (en) * | 2004-02-09 | 2005-08-11 | Carbone Frank L. | Directed energy net shape method and apparatus |
GB0601982D0 (en) * | 2006-02-01 | 2006-03-15 | Rolls Royce Plc | Method and apparatus for examination of objects and structures |
WO2009144489A1 (en) | 2008-05-27 | 2009-12-03 | Bae Systems Plc | Providing an indication of a condition of a structure |
US8082966B2 (en) | 2010-03-12 | 2011-12-27 | Edison Welding Institute, Inc. | System for enhancing sonotrode performance in ultrasonic additive manufacturing applications |
US8706436B2 (en) * | 2011-06-03 | 2014-04-22 | General Electric Company | Manufacture of engineering components with designed defects for analysis of production components |
DE102011113445A1 (en) | 2011-09-15 | 2013-03-21 | Mtu Aero Engines Gmbh | Device and method for the generative production of a component |
US20130101728A1 (en) | 2011-10-21 | 2013-04-25 | John J. Keremes | Additive manufacturing in situ stress relief |
CN104023948B (en) | 2011-12-28 | 2016-07-06 | 阿卡姆股份公司 | For the method and apparatus detecting defect in mouldless shaping |
WO2013159811A1 (en) | 2012-04-24 | 2013-10-31 | Arcam Ab | Safety protection method and apparatus for additive manufacturing device |
-
2015
- 2015-04-08 US US15/302,785 patent/US20170028703A1/en not_active Abandoned
- 2015-04-08 WO PCT/US2015/024863 patent/WO2015157381A1/en active Application Filing
- 2015-04-08 EP EP15776014.1A patent/EP3129772A4/en not_active Withdrawn
-
2019
- 2019-12-04 US US16/703,467 patent/US11020954B2/en active Active
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20110121492A1 (en) * | 2009-11-25 | 2011-05-26 | Eos Gmbh Electro Optical Systems | Method for manufacturing a three-dimensional object |
US8501075B2 (en) * | 2009-11-25 | 2013-08-06 | Eos Gmbh Electro Optical Systems | Method for manufacturing a three-dimensional object |
WO2012097799A2 (en) * | 2011-01-18 | 2012-07-26 | Mtu Aero Engines Gmbh | Process and apparatus for testing the generative production of a component |
US20130088724A1 (en) * | 2011-10-11 | 2013-04-11 | Marc Dubois | Method and apparatus for the inspection of sandwich structures using laser-induced resonant frequencies |
Cited By (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11073501B2 (en) * | 2015-11-13 | 2021-07-27 | Honeywell Federal Manufacturing & Technologies, Llc | System and method for inspecting parts using dynamic response function |
US20190015901A1 (en) * | 2016-01-28 | 2019-01-17 | Siemens Aktiengesellschaft | Method for checking a component to be produced in an additive manner, and device |
US11703481B2 (en) * | 2016-01-28 | 2023-07-18 | Siemens Energy Global Gmbh & Co. | Method for checking a component to be produced in an additive manner, and device |
US10857735B1 (en) * | 2017-04-25 | 2020-12-08 | Hrl Laboratories, Llc | Apparatus and method for additive manufacturing and determining the development of stress during additive manufacturing |
US20200223146A1 (en) * | 2017-06-20 | 2020-07-16 | Carl Zeiss Industrielle Messtechnik Gmbh | Method and Device for Additive Manufacturing |
US11633918B2 (en) * | 2017-06-20 | 2023-04-25 | Carl Zeiss Industrielle Messtechnik Gmbh | Method and device for additive manufacturing utilizing simulation test results of a workpiece |
DE112019002366B4 (en) | 2018-05-08 | 2023-01-05 | Vibrant Corporation | RESONANCE STUDY OF PRODUCTION ITEMS BY REVIEW OF DOCUMENT PRODUCTS |
US11167375B2 (en) | 2018-08-10 | 2021-11-09 | The Research Foundation For The State University Of New York | Additive manufacturing processes and additively manufactured products |
US11426818B2 (en) | 2018-08-10 | 2022-08-30 | The Research Foundation for the State University | Additive manufacturing processes and additively manufactured products |
US11052606B2 (en) | 2018-11-27 | 2021-07-06 | Hamilton Sundstrand Corporation | Platform drop sensor |
WO2020178551A1 (en) * | 2019-03-06 | 2020-09-10 | Hieta Technologies Limited | Manufacturing apparatus and method |
DE102021200473A1 (en) | 2021-01-20 | 2022-07-21 | Volkswagen Aktiengesellschaft | Method and device for the additive manufacturing of at least one component from a shapeless material |
Also Published As
Publication number | Publication date |
---|---|
US20200108594A1 (en) | 2020-04-09 |
EP3129772A4 (en) | 2017-04-26 |
EP3129772A1 (en) | 2017-02-15 |
US11020954B2 (en) | 2021-06-01 |
WO2015157381A1 (en) | 2015-10-15 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US11020954B2 (en) | Method of resonant inspection for additive manufacturing | |
Yasa et al. | A study on the stair stepping effect in direct metal laser sintering of a nickel-based superalloy | |
US9400256B2 (en) | Thermographic inspection techniques | |
CN107116335B (en) | System and method for manufacturing and repairing gas turbine components | |
US20110264413A1 (en) | Method for repairing and/or upgrading a component of a gas turbine | |
US10947849B2 (en) | Systems and methods for recontouring engine components | |
US9618459B2 (en) | Systems and methods for automated composite layup quality assurance | |
Aschenbruck et al. | Recent progress in turbine blade and compressor blisk regeneration | |
US20230043416A1 (en) | Online monitoring of additive manufacturing using acoustic emission methods | |
US10668673B2 (en) | Systems and methods for automated composite layup quality assurance | |
Ünal-Saewe et al. | Process development for tip repair of complex shaped turbine blades with IN718 | |
EP3617994A1 (en) | Blade sentencing | |
EP3181871A1 (en) | Application of combined probabilistic control in gas turbine tuning for power output-emissions parameters with scaling factor, related control systems, computer program products and methods | |
EP3819805B1 (en) | Parametric component design process | |
CA2929830C (en) | System and method for automated part inspection | |
CN115074726B (en) | Laser repair method for special-shaped air film hole of turbine working blade | |
WO2021212888A1 (en) | Method for prefabricating poor fusion defects by controlling lmd process | |
US11460834B2 (en) | Validating an upgrade for a data acquisition system | |
US11821758B2 (en) | Validation of a measurement machine | |
US20230315949A1 (en) | Systems and methods for structural analysis for inspected bladed rotors | |
US20230313685A1 (en) | Bladed rotor inspection, analysis and repair systems and methods | |
US11691336B2 (en) | System and method for additively printing extension segments on workpieces | |
US20230315951A1 (en) | Systems and methods for inspected bladed rotor analysis | |
US20220316858A1 (en) | Intelligent piping inspection machine | |
US20230311252A1 (en) | Blend approach based inspection and analysis systems and methods |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: UNITED TECHNOLOGIES CORPORATION, CONNECTICUT Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:XU, JINQUAN;REEL/FRAME:039967/0086 Effective date: 20140409 |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |