Methods and apparatus for 2-D and 3-D scanning path visualization

Patent metadata

Field	Value
Publication number	US-11537111-B2
Application number	US-202016837721-A
Country	US
Kind code	B2
Filing date	Apr 1, 2020
Priority date	Apr 1, 2020
Publication date	Dec 27, 2022
Grant date	Dec 27, 2022

Abstract

Methods and apparatus for two-dimensional and three-dimensional scanning path visualization are disclosed. An example apparatus includes a parameter determiner to determine at least one of a laser beam parameter setting or an electron beam parameter setting, a melt pool geometry determiner to identify melt pool dimensions using the parameter setting, the melt pool geometry determiner to vary the parameter setting to obtain multiple melt pool dimensions, and a visualization path generator to generate a three-dimensional view of a scanning path for an additive manufacturing process using the identified melt pool dimensions. The visualization path generator adjusts the laser beam parameters based on the generated three-dimensional view.

First claim

What is claimed is:

1. An apparatus comprising:
at least one memory;
instructions in the apparatus; and
processor circuitry to execute the instructions to:
determine at least one of a first laser beam parameter setting or a first electron beam parameter setting;
identify melt pool dimensions using the at least one of the first laser beam parameter setting or the first electron beam parameter setting, the at least one of the first laser beam parameter setting or the first electron beam parameter setting varied to obtain multiple melt pool dimensions, the multiple melt pool dimensions including variable melt pool width or variable melt pool depth;
identify at least one response surface model based on the multiple melt pool dimensions to determine an effect of the variations of the at least one of the first laser beam parameter setting or the first electron beam parameter setting on the melt pool dimensions;
output a three-dimensional model of a scanning path for an additive manufacturing process using the at least one response surface model, the at least one response surface model including a first transfer function to determine a melt pool depth and a second transfer function to determine a melt pool width; and
adjust the at least one of the first laser beam parameter setting or the first electron beam parameter setting based on the three-dimensional model to identify a second laser beam parameter setting or a second electron beam parameter setting, the at least one of the second laser beam parameter setting or the second electron beam parameter setting used to at least one of increase fusion, decrease fusion, or decrease burn back of a build using the additive manufacturing process to improve three-dimensional build quality.

2. The apparatus of claim 1 , wherein the processor circuitry is to generate the at least one response surface model used to determine the melt pool dimensions.

3. The apparatus of claim 2 , wherein the processor circuitry is to receive the first laser beam parameter setting or the first electron beam parameter setting, the first laser beam parameter setting or the first electron beam parameter setting including at least one of a laser beam spot size, a laser power, and a laser speed.

4. The apparatus of claim 1 , wherein the three-dimensional model includes a contour area, a bulk area, or a down-skin area.

5. The apparatus of claim 1 , wherein the three-dimensional model permits display of build areas showing a lack of fusion or excess melting.

6. The apparatus of claim 1 , wherein the processor circuitry is to generate a three-dimensional view of a scanning path based on a number of melt layers.

7. The apparatus of claim 6 , wherein the processor circuitry is to output a percentage of material volume melted per the number of melt layers.

8. The apparatus of claim 1 , further including a laser source to initiate the additive manufacturing process based on the output.

9. A method comprising:
determining at least one of a first laser beam parameter setting or a first electron beam parameter setting;
identifying melt pool dimensions using the at least one of the first laser beam parameter setting or the first electron beam parameter setting, the at least one of the first laser beam parameter setting or the first electron beam parameter setting varied to obtain multiple melt pool dimensions, the multiple melt pool dimensions including variable melt pool width or variable melt pool depth;
identifying at least one response surface model based on the multiple melt pool dimensions to determine an effect of the variations in the at least one of the first laser beam parameter setting or the first electron beam parameter setting on the melt pool dimensions;
outputting a three-dimensional model of a scanning path for an additive manufacturing process using the at least one response surface model, the at least one response surface model including a first transfer function to determine a melt pool depth and a second transfer function to determine a melt pool width; and
adjusting the at least one of the first laser beam parameter setting or the first electron beam parameter setting based on the three-dimensional model to identify a second laser beam parameter setting or a second electron beam parameter setting, the at least one of the second laser beam parameter setting or the second electron beam parameter setting used to at least one of increase fusion, decrease fusion, or decrease burn back of a build using the additive manufacturing process to improve three-dimensional build quality.

10. The method of claim 9 , further including generating the at least one response surface model used to determine the melt pool dimensions.

11. The method of claim 10 , further including receiving the first laser beam parameter setting or the first electron beam parameter setting, the first laser beam parameter setting or the first electron beam parameter setting including at least one of a laser beam spot size, a laser power, and a laser speed.

12. The method of claim 9 , wherein the three-dimensional geometric model includes a contour area, a bulk area, or a down-skin area.

13. The method of claim 9 , further including displaying build areas showing a lack of fusion or excess melting.

14. The method of claim 9 , further including generating a three-dimensional view of a scanning path based on a number of melt layers.

15. The method of claim 14 , further including outputting a percentage of material volume melted per the number of melt layers.

16. A non-transitory computer readable storage medium comprising instructions that, when executed, cause a processor to at least:
determine at least one of a first laser beam parameter setting or a first electron beam parameter setting;
identify melt pool dimensions using the at least one of the first laser beam parameter setting or the first electron beam parameter setting, the at least one of the first laser beam parameter setting or the first electron beam parameter setting varied to obtain multiple melt pool dimensions, the multiple melt pool dimensions including variable melt pool width or variable melt pool depth;
identify at least one response surface model based on the multiple melt pool dimensions to determine an effect of the variation in the at least one of the first laser beam parameter setting or the first electron beam parameter setting on the melt pool dimensions;
output a three-dimensional model of a scanning path for an additive manufacturing process using the at least one response surface model, the at least one response surface model including a first transfer function to determine a melt pool depth and a second transfer function to determine a melt pool width; and
adjust the at least one of the first laser beam parameter setting or the first electron beam parameter setting based on the three-dimensional model to identify a second laser beam parameter setting or a second electron beam parameter setting, the at least one of the second laser beam parameter setting or the second electron beam parameter setting used to at least one of increase fusion, decrease fusion, or decrease burn back of a build using the additive manufacturing process to improve three-dimensional build quality.

17. The non-transitory computer readable storage medium of claim 16 , wherein the instructions, when executed, cause a processor to generate the at least one response surface model used to determine the melt pool dimensions.

18. The non-transitory computer readable storage medium of claim 17 , wherein the instructions, wh

Assignees

• Gen Electric

Inventors

• Yang Pinghai
• Sun Hongqing
• Acosta Manuel
• Fairman Ruben E

Classifications

• B22F10/366

  Scanning parameters, e.g. hatch distance or scanning strategy · CPC title

• G05B2219/40091

  Tele-programming by graphical simulation · CPC title

• G05B19/41885 Primary

  characterised by modeling, simulation of the manufacturing system · CPC title

• G05B2219/49007

  Making, forming 3-D object, model, surface · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title