Powder flow measurement in additive manufacturing systems

Patent metadata

Field	Value
Publication number	US-12454007-B2
Application number	US-202217932959-A
Country	US
Kind code	B2
Filing date	Sep 16, 2022
Priority date	Sep 23, 2021
Publication date	Oct 28, 2025
Grant date	Oct 28, 2025

Abstract

A system may include one or more computing devices configured to receive image data representing illuminated powder of a powder stream between a powder delivery device of an additive manufacturing system and a build surface of a component; determine at least one metric associated with the powder stream based on the received image data; determine whether the at least one metric indicates an abnormal state of the at least one metric; and cause the additive manufacturing system to perform at least one action in response to determining that the at least one metric indicates the abnormal state.

First claim

What is claimed is:

1 . A system comprising:
one or more computing devices configured to:
receive image data representing illuminated powder of a powder stream between a powder delivery device of an additive manufacturing system and a build surface of a component, wherein the additive manufacturing system is configured to simultaneously deliver energy to form a melt pool in the build surface and deliver the powder stream to the melt pool, and wherein the image data represents illuminated powder of the powder stream while the powder stream is delivered to the melt pool;
determine at least one metric associated with the powder stream based on the received image data;
determine whether the at least one metric indicates an abnormal state of the at least one metric; and
cause the additive manufacturing system to perform at least one action in response to the at least one metric indicating the abnormal state.

2 . The system of claim 1 , wherein the one or more computing devices is configured to determine the at least one metric by at least:
determining a mass flow rate or powder distribution within the powder stream.

3 . The system of claim 2 , wherein the one or more computing devices is configured to determine the at least one metric by at least:
determining a mass flow rate or powder distribution for each region of interest of at least one region of interest of the powder stream.

4 . The system of claim 3 , wherein the one or more computing devices is configured to determine whether the at least one metric indicates an abnormal state by at least:
comparing the at least one metric associated with each region of interest to the at least one metric associated with each other region of interest and determining that the at least one metric indicates the abnormal state in response to the comparison showing differences between the metrics above a threshold difference value.

5 . The system of claim 2 , wherein the one or more computing devices is configured to determine the at least one metric by at least:
determining a radial powder distribution for each region of interest of at least one region of interest of the powder stream.

6 . The system of claim 1 , wherein the one or more computing devices is configured to determine whether the at least one metric indicates the abnormal state of the at least one metric by at least:
comparing the at least one metric to a baseline range of values and determining that the at least one metric indicates the abnormal state in response to the at least one metric being outside of the baseline range of values.

7 . The system of claim 1 , wherein the one or more computing devices is configured to cause the additive manufacturing system to perform at least one action by at least:
controlling at least one operating parameter of the additive manufacturing system.

8 . The system of claim 7 , wherein the at least one parameter comprises at least one of a powder feed rate or a carrier gas flow rate.

9 . The system of claim 8 , wherein the at least one parameter comprises at least one of a powder feed rate to a selected nozzle of the powder delivery device or a carrier gas flow rate to a selected nozzle of the powder delivery device.

10 . The system of claim 7 , wherein the at least one parameter comprises a position of the powder delivery device.

11 . The system of claim 10 , wherein the one or more computing devices is configured to cause the powder delivery device to move against a scrubbing surface.

12 . The system of claim 7 , wherein the at least one parameter comprises a purge gas flow rate, and wherein the one or more computing devices is configured to cause a relatively high purge gas flow rate through the powder delivery device.

13 . The system of claim 7 , wherein the one or more computing devices is configured to cause the additive manufacturing system to perform the at least one action by at least placing the powder delivery device in a recovery state while controlling the at least one operating parameter of the additive manufacturing system.

14 . A method comprising:
receiving, by one or more computing devices, image data representing illuminated powder of a powder stream between a powder delivery device of an additive manufacturing system and a build surface of a component, wherein the additive manufacturing system is configured to simultaneously deliver energy to form a melt pool in the build surface and deliver the powder stream to the melt pool, and wherein the image data represents illuminated powder of the powder stream while the powder stream is delivered to the melt pool; determining, by the one or more computing devices, at least one metric associated with the powder stream based on the received image data; determining, by the one or more computing devices, whether the at least one metric indicates an abnormal state of the at least one metric; and causing, by the one or more computing devices, the additive manufacturing system to perform at least one action in response to determining that the at least one metric indicates the abnormal state.

15 . The method of claim 14 , wherein determining the at least one metric comprises determining, by the one or more computing devices, a mass flow rate or powder distribution within the powder stream.

16 . The method of claim 15 , wherein determining the at least one metric comprises determining, by the one or more computing devices, a mass flow rate or powder distribution for each region of interest of at least one region of interest of the powder stream.

17 . The method of claim 16 , wherein determining whether the at least one metric indicates an abnormal state comprises comparing, by the one or more computing devices, the at least one metric associated with each region of interest to the at least one metric associated with each other region of interest and determining that the at least one metric indicates the abnormal state in response to the comparison showing differences between the metrics above a threshold difference value.

18 . The method of claim 15 , wherein determining the at least one metric comprises determining, by the one or more computing devices, a radial powder distribution for each region of interest of at least one region of interest of the powder stream.

19 . The method of claim 14 , wherein determining whether the at least one metric indicates the abnormal state of the at least one metric comprises comparing, by the one or more computing devices, the at least one metric to a baseline range of values and determining that the at least one metric indicates the abnormal state in response to the at least one metric being outside of the baseline range of values.

20 . The method of claim 14 , wherein causing the additive manufacturing system to perform at least one action comprises controlling, by the one or more computing devices, at least one operating parameter of the additive manufacturing system.

Assignees

• Rolls Royce Corp

Inventors

• Nelson Scott
• Grubbs John
• Shuck Quinlan Yee

Classifications

• G05B19/4099

  Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing · CPC title

• G05B2219/49023

  3-D printing, layer of powder, add drops of binder in layer, new powder · CPC title

• G06T7/0004

  Industrial image inspection · CPC title

• G06T2207/30108

  Industrial image inspection · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title