JP7024981B2 - 付加製造動作中の放射熱エネルギーを測定するためのシステムおよび方法 - Google Patents
付加製造動作中の放射熱エネルギーを測定するためのシステムおよび方法 Download PDFInfo
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Description
本出願は、それぞれ「Systems And Methods For Measuring Energy Input During An Additive Manufacturing Operation」と題する、2017年8月1日に出願された米国仮特許出願第62/540,016号、2018年2月21日に出願された第62/633,487号、および2018年3月15日に出願された62/643,457号の優先権を主張し、その開示は、その全体があらゆる目的のために参照により本明細書に組み込まれる。
統合されたフォトダイオード電圧418を使用して、TEDi計算のpdoniを決定できる。
ここで、Vは各スキャンレットに対して決定された平均電圧、Nはサンプル数である。図6Dでは、20サンプルセグメントの平均電圧は、データの幅が固定されているため、信号の積分に相当する。
スキャンの開始と終了のx座標とy座標は指定され得るか、1つまたは複数の直接センサ測定値に基づいて決定され得る。
TEDは、レーザパワー、レーザ速度、ハッチ間隔など、ユーザ定義のすべてのレーザ粉末床融合プロセスパラメータに敏感である。TED値は、ベースラインデータセットとのIPQM比較を使用した分析に使用され得る。結果のIPQMは、レーザスキャンごとに決定され得、点群を使用してグラフまたは3次元で表示され得る。図4Gは、例示的なグラフを示している。図4Hは、例示的な点群を示している。
リコータアームショートフィードのTED分析
熱エネルギー密度とグローバルエネルギー密度
PTOTAL LASER POWER=POPTICAL LOSSES AT THE LASER+PABSORPTION BY CHAMBER GAS+PREFLECTION+PPARTICLE AND PLUME INTERACTIONS+PPOWER NEEDED TO SUSTAIN MELT POOL+PCONDUCTION LOSSES+PRADIATION LOSSES+PCONVECTION LOSSES+PVAPORIZATION LOSSES 式(13)
VVOLTAGE USED BY TED={PRADIATED-PVIEW FACTOR-POPTICAL LOSSES AT RADIATED WAVELENGTHS-PSENSOR LOSS FACTOR}*(SENSOR SCALING FACTOR)式(15)
GED=(BEAM POWER)/{(TRAVEL SPEED)*(HATCH SPACING)} 式(16)
Claims (19)
- ビルド面にわたるエネルギー源の複数のスキャンを生成するステップと、
前記ビルド面を監視する光学センサを使用して、前記複数のスキャンのそれぞれの間に前記ビルド面から放射されるエネルギー量を測定するステップと、
前記複数のスキャン中に横断した前記ビルド面の面積を決定するステップと、
前記放射されたエネルギー量と前記複数のスキャンが横断した前記ビルド面の面積に基づいて、前記複数のスキャンが横断した前記ビルド面の面積の熱エネルギー密度を決定するステップと、
前記熱エネルギー密度を前記ビルド面の1つの位置にマッピングするステップと、
前記熱エネルギー密度が、熱エネルギー密度値の所定の範囲外であることを決定するステップと、
その後、前記ビルド面の前記1つの位置にわたる前記エネルギー源の後続のスキャンを調整するステップと
を含む、付加製造方法。 - 前記エネルギー量を測定するステップが、前記光学センサからのセンサ読み取り値を受信するステップを含む、請求項1に記載の付加製造方法。
- 前記横断したビルド面の面積を決定するステップが、
前記複数のスキャンの第1のスキャンの開始点を決定するステップと、
前記第1のスキャンの終了点を決定するステップと、
前記開始点と前記終了点との間の距離を計算することにより、前記第1のスキャンの長さを決定するステップと
を含む、請求項1に記載の付加製造方法。 - プロセスパラメータに関連付けられた制御信号を送信するステップ
をさらに含む、請求項1に記載の付加製造方法。 - 前記エネルギー源が、レーザおよび電子ビームの少なくとも一方に対応する、請求項1に記載の付加製造方法。
- 前記熱エネルギー密度をマッピングするステップが、
前記ビルド面にわたる前記エネルギー源の経路を示すエネルギー源駆動信号データを受信するステップと、
前記エネルギー源駆動信号データを使用して、前記複数のスキャンのそれぞれの位置を決定するステップと
を含む、請求項1に記載の付加製造方法。 - 前記エネルギー源に関連付けられた位置データを受信するステップ
をさらに含む、請求項1に記載の付加製造方法。 - エネルギー源駆動信号データを受信するステップであって、前記エネルギー源駆動信号データは、前記エネルギー源がオンになったときと前記エネルギー源がオフになったときを示す、ステップと
をさらに含む、請求項1に記載の付加製造方法。 - ビルド面にわたるエネルギー源の複数のスキャンを生成するステップと、
前記複数のスキャンを含むグリッド領域を決定するステップであって、前記グリッド領域はグリッド面積によって特徴付けられる、ステップと、
光学センサを使用して、前記複数のスキャンのそれぞれの間にセンサ読み取り値を生成するステップと、
前記センサ読み取り値を使用して、前記複数のスキャン中に前記ビルド面から放射されるエネルギーの合計量を決定するステップと、
前記放射されるエネルギーの合計量と前記グリッド面積に基づいて、前記グリッド領域に関連付けられた熱エネルギー密度を計算するステップと、
前記グリッド領域に関連付けられた前記熱エネルギー密度が、熱エネルギー密度値の所定の範囲外であることを決定するステップと、
その後、前記エネルギー源の出力を調整するステップと
を含む、付加製造方法。 - 前記熱エネルギー密度が、前記放射されるエネルギーの合計量を前記グリッド面積で除算することにより決定される、請求項9に記載の付加製造方法。
- 前記グリッド領域の幅が、前記複数のスキャンのそれぞれの長さに応じてサイズ設定される、請求項9に記載の付加製造方法。
- 前記複数のスキャンを含むグリッド領域を決定するステップが、
前記ビルド面にわたる前記エネルギー源の経路を示すエネルギー源駆動信号データを受信するステップと、
前記エネルギー源駆動信号データに基づいて、前記グリッド領域の位置、形状、およびサイズを画定するステップと
を含む、請求項9に記載の付加製造方法。 - 前記エネルギー源駆動信号データが、前記複数のスキャンのうちの2つ以上のスキャンの間の距離を含む、請求項12に記載の付加製造方法。
- ビルド面の一部を、それぞれがグリッド領域面積を有する複数のグリッド領域を含むグリッドとして、画定するステップと、
前記ビルド面にわたるエネルギー源の複数のスキャンを生成するステップと、
光学センサを使用して、前記複数のスキャンのそれぞれの間にセンサ読み取り値を生成するステップと、
前記複数のスキャンのそれぞれに対して、前記複数のセンサ読み取り値のそれぞれの部分を前記複数のグリッド領域のそれぞれ1つにマッピングするステップと、
前記複数のグリッド領域のそれぞれについて、
各グリッド領域にマッピングされた前記センサ読み取り値を合計するステップと、
前記合計されたセンサ読み取り値と前記グリッド領域面積に基づいてグリッドベースの熱エネルギー密度を計算するステップと、
前記複数のグリッド領域の1つまたは複数に関連付けられた前記グリッドベースの熱エネルギー密度が、熱エネルギー密度値の所定の範囲外であることを決定するステップと、
その後、前記エネルギー源の出力を調整するステップと
を含む、付加製造方法。 - 前記ビルド面全体に粉末層を設けるステップと、
前記粉末層全体で前記エネルギー源の追加の複数のスキャンを生成するステップであって、前記追加の複数のスキャンの少なくともいくつかの特性は、前記複数のグリッド領域の1つまたは複数の前記計算されたグリッドベースの熱エネルギー密度に基づく、ステップと、
をさらに含む、請求項14に記載の付加製造方法。 - 前記計算されたグリッドベースの熱エネルギー密度に基づいて、前記複数のスキャンのうちの1つの少なくとも一部の間に、前記エネルギー源の1つまたは複数の入力パラメータが変更される、請求項14に記載の付加製造方法。
- 前記センサ読み取り値のそれぞれの部分をマッピングするステップが、前記複数のスキャンの1つに対する前記複数のセンサ読み取り値のすべてを前記複数のグリッド領域の1つまたは複数にマッピングするステップを含む、請求項14に記載の付加製造方法。
- 前記ビルド面が、前記グリッドの面積に等しい面積によって特徴付けられる、請求項14に記載の付加製造方法。
- 前記グリッド領域が、前記ビルド面全体に均一に分布している、請求項14に記載の付加製造方法。
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