Method for rapid characterization of metallic powders

Patent metadata

Field	Value
Publication number	US-12566138-B2
Application number	US-202418415358-A
Country	US
Kind code	B2
Filing date	Jan 17, 2024
Priority date	Jan 17, 2024
Publication date	Mar 3, 2026
Grant date	Mar 3, 2026

Abstract

A method for characterization of metallic powder including presenting a metallic powder sample to a laser and detector system, wherein the metallic powder sample passes through the laser and detector system via a sample introducer; applying a pulsed laser beam to a first location in the metallic powder sample to provide a first micro-plasma at the first location in the metallic powder sample when the pulsed laser beam terminates, the micro-plasma cools to provide spectral emissions at the first location; collecting the spectral emissions at the first location in the metallic powder sample with a detector; analyzing the spectral emissions at the first location to provide a spectral analysis dataset; and identifying inclusions at the first location in the metallic powder sample.

First claim

What is claimed is:

1 . A method for characterization of metallic powder comprising:
presenting a metallic powder sample to a laser and detector system, wherein the metallic powder sample passes through the laser and detector system via a sample introducer, wherein the sample introducer concentrates inclusions within the metallic powder sample; applying a pulsed laser beam to a first location in the metallic powder sample to provide a first micro-plasma at the first location in the metallic powder sample, when the pulsed laser beam terminates, the micro-plasma cools to provide spectral emissions at the first location; collecting the spectral emissions at the first location in the metallic powder sample with a detector; analyzing the spectral emissions at the first location to provide a spectral analysis dataset; and identifying the inclusions at the first location in the metallic powder sample.

2 . The method of claim 1 , wherein the identifying inclusions at the first location in the metallic powder sample comprises comparing spectral emissions of a control sample to the spectral emissions at the first location to determine the presence or absence of inclusions in the metallic powder sample.

3 . The method of claim 2 , wherein the spectral emissions of the control sample are acquired by presenting a control metallic powder sample to the laser and detector system;
applying the pulsed laser beam to a location in the control metallic powder sample to provide a control micro-plasma at the location in the control metallic powder sample when the pulsed laser beam terminates, the control micro-plasma cools to provide spectral emissions of the control sample at the location in the control metallic powder sample; and collecting the spectral emissions of the control sample at the location in the control metallic powder sample with the detector.

4 . The method of claim 1 , further comprising presenting the metallic powder sample to the laser and detector system;
applying the pulsed laser beam to a plurality of locations in the metallic powder sample to provide a plurality of micro-plasmas at the plurality of locations in the metallic powder sample, when the pulsed laser beam terminates, the plurality of micro-plasmas cool to provide a plurality of spectral emissions at the plurality of locations in the metallic powder sample; collecting the plurality of spectral emissions at the plurality of locations in the metallic powder sample with a detector; analyzing the plurality of spectral emissions to provide a plurality of spectral analyses datasets; and identifying inclusions at the plurality of locations in the metallic powder sample.

5 . The method of claim 1 further comprising presenting the metallic powder sample to a spark-induced breakdown spectroscopy system, a laser-induced breakdown spectroscopy system, a near-infrared spectroscopy system, a Raman spectroscopy system, an infrared spectroscopy system, a photoluminescence spectroscopy system, an infrared thermography system, an x-ray fluorescence spectroscopy system, a radiography system, a terahertz spectroscopy system, a fluorescence spectroscopy system, a machine vision system, an ultrasonic testing system, an eddy current testing system, or an x-ray computer tomography system;
applying energy to the metallic powder sample to provide an energy output of the sample;
collecting the energy output of the sample with a second detector;
analyzing the energy output to provide an energy output analysis dataset; and
combining the information in the spectral analysis dataset and the energy output analysis dataset to identify inclusions in the sample.

6 . The method of claim 1 further comprising presenting the metallic powder sample to a spark-induced breakdown spectroscopy system, a laser-induced breakdown spectroscopy system, a near-infrared spectroscopy system, a Raman spectroscopy system, an infrared spectroscopy system, a photoluminescence spectroscopy system, an infrared thermography system, an x-ray fluorescence spectroscopy system, a radiography system, a terahertz spectroscopy system, a fluorescence spectroscopy system, a machine vision system, an ultrasonic testing system, an eddy current testing system, an x-ray computer tomography system, or a combination thereof;
applying a plurality of energy types to a plurality of locations in the metallic powder sample to provide a plurality of energy outputs at the plurality of locations in the sample;
collecting the plurality of energy outputs at the plurality of locations in the metallic powder sample with a plurality of detectors;
analyzing the plurality of energy outputs to provide a plurality of energy output analyses datasets; and
combining the information in the spectral analysis dataset and the plurality of energy output analyses datasets to identify inclusions in the metallic powder sample.

7 . The method of claim 1 , wherein the inclusions are off-chemistry metallic particles, non-metallic particles, or a combination thereof.

8 . The method of claim 1 , further comprising characterization of the inclusions at the location in the metallic powder sample.

9 . The method of claim 8 , wherein the characterization of the inclusions comprises chemical characterization of types of non-metallic particles and/or types of off-chemistry metallic particles in the metallic powder sample.

10 . The method of claim 1 , wherein the applying of the pulsed laser beam and the collecting of the spectral emissions are performed in air, under an inert atmosphere, or under reduced pressure.

11 . The method of claim 10 , wherein the inert atmosphere is nitrogen, a noble gas, or a combination thereof, wherein the reduced pressure is partial vacuum of 0.1 kilopascals to 100 kilopascals, or wherein the reduced pressure is a full vacuum of 0.1 pascals to less than 100 kilopascals.

12 . The method of claim 6 , wherein the applying of the plurality of energy types and the collecting of the plurality of energy outputs are performed in air, under an inert atmosphere, under reduced pressure, or a combination thereof.

13 . The method of claim 1 , wherein cleanliness of the metallic powder sample is measured within 30 seconds to 2 days.

14 . A laser and detector system for characterization of metallic powders comprising:
a sample introducer that concentrates inclusions from the metallic powders; a laser source for applying a pulsed laser beam to a first location in the metallic powders to provide a first micro-plasma at the first location; a detector for collecting a spectral emission from the micro-plasma at the first location as the micro-plasma cools; and an analysis system for analyzing the spectral emission at the first location to provide a spectral analysis dataset.

15 . The laser and detector system of claim 14 , further comprising a plurality of n lasers and a plurality of m detectors.

16 . The laser and detector system of claim 15 , wherein n is 1 to 100 and m is 1 to 100.

17 . The laser and detector system of claim 14 , further comprising a spark-induced breakdown spectroscopy system, a laser-induced breakdown spectroscopy system, a near-infrared spectroscopy system, a Raman spectroscopy system, an infrared spectroscopy system, a photoluminescence spectroscopy system, an infrared thermography system, an x-ray fluorescence spectroscopy system, a radiography system, a terahertz spectroscopy system, a fluorescence spectroscopy system, a machine vision system, an ultrasonic testing system, an eddy current testing system, an x-ray computer tomography sys

Assignees

• Rtx Corp

Inventors

• Furrer David U
• Cernatescu Iuliana
• Lucas Marcel
• Burlatsky Sergei F

Classifications

• G01N2201/06113

  Coherent sources; lasers · CPC title

• G01N33/202

  Constituents thereof · CPC title

• G01N33/0091

  Powders · CPC title

• G01N2015/03

  Electro-optical investigation of a plurality of particles, the analyser being characterised by the optical arrangement · CPC title

• G01N2015/0096

  Investigating consistence of powders, dustability, dustiness · CPC title