Tunable system and method for stress resolution in additive manufacturing

Patent metadata

Field	Value
Publication number	US-2021354396-A1
Application number	US-202016872618-A
Country	US
Kind code	A1
Filing date	May 12, 2020
Priority date	May 12, 2020
Publication date	Nov 18, 2021
Grant date	—

Abstract

Systems and methods resolve stresses in additive manufacturing. A stress resolution profile including frequency and amplitude parameters of an ultrasonic input are determined based on physical properties of the product. Successive layers of a material are added and energy is applied to incorporate the material of each layer into the product. An ultrasonic input is applied with the determined parameters to resolve stress as the product is built up. The ultrasonic input is varied as a depth of the material incorporated into the product increases.

First claim

What is claimed is:

1 . A method of stress resolution in forming a product by additive manufacturing, the method comprising:
determining stress resolution profile parameters of an ultrasonic input based on physical properties of the product; adding successive layers of a material to build the product; adding energy to incorporate the material of each layer into the product; applying, by an ultrasonic transducer, the ultrasonic input with the determined stress resolution profile parameters to resolve stress as the product is built up; varying the ultrasonic input as a depth of the material incorporated into the product increases.

2 . The method of claim 1 , wherein the determined stress resolution profile parameters include a determined frequency of the ultrasonic input and comprising:
evaluating whether the determined frequency corresponds to a resonant frequency of the product; and modifying the determined parameters when the determined frequency corresponds to a resonant frequency.

3 . The method of claim 1 , wherein the determined parameters include a determined frequency of the ultrasonic input and a determined amplitude of the ultrasonic input and comprising tuning the ultrasonic input to each individual layer throughout the build of the product.

4 . The method of claim 1 , comprising determining whether ultrasonic input is needed for each individual layer of the build, prior to applying the ultrasonic input.

5 . The method of claim 4 , wherein determining whether ultrasonic input is needed comprises evaluating stored data for each individual layer of the build.

6 . The method of claim 4 , wherein determining whether ultrasonic input is needed comprises measuring, by a sensor, whether the product is distorting.

7 . The method of claim 1 , comprising:
determining resonant frequencies for the product at various stages of the build; and avoiding the resonant frequency for the respective layer of the build when applying the ultrasonic input.

8 . The method of claim 1 , comprising applying the ultrasonic input concurrent with adding energy to incorporate the material into the product.

9 . The method of claim 1 , comprising:
building the product on a build platform; and coupling the ultrasonic transducer with the build platform.

10 . The method of claim 1 , comprising:
collecting measurement data of the product during the build; and storing the measurement data to provide customized stress resolution treatment for build of the product.

11 . A stress resolution system for forming a product by additive manufacturing, the system comprising:
a build platform; an ultrasonic transducer coupled with the build platform; a material delivery system configured to add successive layers of a material to build the product; a laser system configured to add energy to incorporate the material of each layer into the product; and a controller configured to:
apply a signal to the ultrasonic transducer to produce an ultrasonic input having parameters to resolve stress as the product is built up; and
vary the ultrasonic input as a depth of the material incorporated into the product increases.

12 . The system of claim 11 , wherein:
the parameters include a determined frequency of the ultrasonic input; and the controller is configured to:
evaluate whether the determined frequency corresponds to a resonant frequency of the product, and
modify the determined parameters when the determined frequency corresponds to a resonant frequency.

13 . The system of claim 11 , wherein the parameters include a determined frequency of the ultrasonic input and a determined amplitude of the ultrasonic input, and wherein the controller is configured to tune the ultrasonic input to each individual layer throughout the build of the product.

14 . The system of claim 11 , wherein the controller is configured to determine whether ultrasonic input is needed for each individual layer of the build, prior to applying the ultrasonic input.

15 . The system of claim 14 , wherein the controller is configured to determine whether ultrasonic input is needed by evaluating stored data for each individual layer of the build.

16 . The system of claim 14 , comprising a sensor configured to detect distortion of the product; and wherein the controller is configured to determine whether ultrasonic input is needed by monitoring the sensor.

17 . The system of claim 11 , wherein the controller is configured to avoid a resonant frequency for the layer of the build when applying the ultrasonic input.

18 . The system of claim 11 , wherein the controller is configured to apply the ultrasonic input concurrent with adding energy to incorporate the material into the product.

19 . The system of claim 11 , wherein the controller is configured to:
collect measurement data of the product during the build; and store the measurement data to provide customized stress resolution treatment for build of the product.

20 . A method of stress resolution in forming a product by additive manufacturing, the method comprising:
determining frequency and amplitude parameters of an ultrasonic input based on physical properties of the product; adding, by a material delivery system, successive layers of a material to build the product; adding energy by a laser system to incorporate the material of each layer into the product; applying, by an ultrasonic transducer, the ultrasonic input with the determined parameters to resolve stress as the product is built up; varying the frequency and amplitude as a depth of the material incorporated into the product increases; and applying, by the ultrasonic transducer, an acoustic profile tailored to settle and compact the material.

Assignees

• Honeywell Int Inc

Inventors

• Bowler John
• Colvin Gregory
• Sundarraj Suresh

Classifications

• Y02P10/25

  Process efficiency · CPC title

• B23K20/10

  making use of vibrations, e.g. ultrasonic welding · CPC title

• B23K11/0013

  welding for purposes other than joining, e.g. build-up welding · CPC title

• B22F2202/01

  Use of vibrations · CPC title

• B22F10/50

  Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up · CPC title