Method and Device for Additive Manufacturing

Patent metadata

Field	Value
Publication number	US-2020223146-A1
Application number	US-201916722159-A
Country	US
Kind code	A1
Filing date	Dec 20, 2019
Priority date	Jun 20, 2017
Publication date	Jul 16, 2020
Grant date	—

Abstract

Methods and devices for additive manufacturing of workpieces are provided. For analysis during production, a test is carried out using a selected test method. The test results are compared with simulated test results derived during a simulation of the manufacturing and testing. The test may use one or more of a laser ultrasound test unit, an electronic laser speckle interferometry test unit, an infrared thermography test unit, or an x-ray test unit.

First claim

What is claimed is:

1 . A method for additive manufacturing, the method comprising:
obtaining manufacturing data for a workpiece, wherein the manufacturing data defines a plurality of layers of the workpiece; simulating additive manufacturing of the workpiece using the manufacturing data, thereby creating a simulated workpiece having a plurality of simulated layers; simulating measurement of the plurality of simulated layers in order to determine simulated test results for the workpiece; physically producing a set of layers of the plurality of layers using an additive manufacturing process according to the manufacturing data; measuring the produced set of layers in order to obtain measured test results for the workpiece; evaluating the measured test results using the simulated test results to determine whether manufacturing is acceptable; in response to the evaluating indicating acceptable manufacturing, repeating the physically producing, the measuring, and the evaluating for further sets of layers of the plurality of layers; and in response to the evaluating indicating unacceptable manufacturing, performing a remedial measure.

2 . The method of claim 1 , wherein the evaluating comprises supplying the measured test results and the simulated test results to a trained machine learning model.

3 . The method of claim 1 , wherein the evaluating comprises comparing the simulated test results with the measured test results.

4 . The method of claim 1 , wherein the remedial measure comprises changing process parameters for physically producing subsequent sets of layers.

5 . The method of claim 1 , wherein the remedial measure comprises rejecting the workpiece.

6 . The method of claim 1 , wherein the set of layers comprises at least one of a single layer, a plurality of layers, and a partial layer.

7 . The method of claim 1 , wherein the evaluating comprises using a predefined correlation of differences between the measured test results and the simulated test results with component properties.

8 . The method of claim 1 , wherein the measuring comprises carrying out a laser ultrasound process on the produced set of layers.

9 . The method of claim 8 , wherein:
the physically producing is performed in a powder bed comprising a powder material, the laser ultrasound process uses a laser beam having a pulse frequency of less than f max =v M /(d M +s M ), v M is a speed of sound in the powder material, d M is a mean particle diameter of the powder material, and s M is a standard deviation of a size distribution of particles of the powder material.

10 . The method of claim 1 , wherein the measuring comprises carrying out electronic laser speckle interferometry.

11 . The method of claim 1 , wherein the measuring comprises carrying out infrared thermography.

12 . The method of claim 1 , wherein the measuring comprises carrying out an x-ray examination.

13 . A device for additive manufacturing, the device comprising:
a simulation device configured to:
simulate additive manufacturing of a workpiece and
simulate test results during manufacturing in order to determine simulated test results for the workpiece;
a manufacturing device configured to perform additive manufacturing of the workpiece layer by layer; and a test device configured to test the workpiece during the additive manufacturing in order to obtain measured test results, wherein the test device is configured to test the workpiece during manufacturing in order to determine measured test results and wherein the simulation device is configured to
evaluate the measured test results using the simulated test results and
perform a remedial measure in response to the evaluation indicating unacceptable manufacturing of the workpiece.

14 . The device of claim 13 , wherein the test device comprises at least one of a laser ultrasound test device, an electronic laser speckle interferometry test device, an infrared thermography test device, and an x-ray test device.

15 . A method for additive manufacturing, the method comprising:
manufacturing a workpiece by an additive manufacturing method and during the manufacturing, analyzing the workpiece by a combination of infrared thermography and electronic laser speckle interferometry.

16 . The method of claim 15 , wherein the analyzing comprises an evaluation using machine learning.

17 . A device for manufacturing a workpiece, the device comprising:
a manufacturing device configured to produce the workpiece using additive manufacturing and an analysis device configured to analyze the workpiece during the manufacturing, wherein the analysis device comprises:
a unit for electronic laser speckle interferometry and
a unit for infrared thermography.

Assignees

• Zeiss Carl Industrielle Messtechnik Gmbh

Inventors

• Totzeck Michael
• Krautz Danny
• Spengler Diana
• Wolf Uwe
• Hagen Christoph-Hilmar Graf Vom
• Holzner Christian
• Omlor Lars

Classifications

• G01N29/2418 Primary

  using optoacoustic interaction with the material, e.g. laser radiation, photoacoustics (photoacoustic cells G01N21/1702; measuring characteristics of vibrations by using radiation-sensitive means G01H9/00; acousto-optical conversion techniques for short-range imaging G01S15/8965; sound-producing devices using laser bundle G10K15/046) · CPC title

• B22F12/90

  Means for process control, e.g. cameras or sensors · CPC title

• B22F10/85

  for controlling or regulating additive manufacturing processes · CPC title

• B22F10/80

  Data acquisition or data processing · CPC title

• B22F10/60

  Treatment of workpieces or articles after build-up · CPC title