Additive manufacturing system with ultrasonic inspection and method of operation
An additive manufacturing system includes an ultrasonic inspection system integrated in such a way as to minimize time needed for an inspection process. The inspection system may have an ultrasonic phased array integrated into a build table for detecting defects in each successive slice of a workpiece and such that each slice may be re-melted if and when defects are detected.
1. A method of operating an additive manufacturing system, the method comprising the steps of:
forming a slice of a workpiece with a build table, the build table configured to support a powder bed, the build table comprising a top side and a bottom side, the build table further comprising a sheet defining the top side of the build table, the sheet comprising a top face and a bottom face; and
performing an ultrasonic inspection of the slice with an ultrasonic inspection system, the ultrasonic inspection system comprising a plurality of ultrasonic sensors, the plurality of ultrasonic sensors forming a sensory array integrated into the build table between the top side and the bottom side of the build table.
2. The method of claim 1 , wherein the top face is configured to directly support a bottom slice of a plurality of slices and wherein each sensor of the plurality of sensors includes a buffer in direct contact with the bottom face, each buffer located between a respective transducer of each sensor of the plurality of sensors and the bottom face.
3. The method of claim 2 , wherein the ultrasonic inspection system further comprises a controller having a modeling of the workpiece divided into the plurality of slices and stored electronically.
4. The method of claim 3 , further comprising the step of:
operating the sensory array in a phase array mode to effect sonic wave activation at variable angles to a top surface of a top slice of the plurality of slices.
5. The method of claim 1 , further comprising the steps of:
detecting a defect in the workpiece; and
re-forming the slice.
6. The method of claim 5 , further comprising the steps of:
laying a powder bed in a first layer upon a build table;
melting at least in-part the first layer, with an energy gun, into at least one first melt pool; and
solidifying the melt pool thereby forming the slice as a bottom slice directly upon a build table.
7. The method of claim 6 , further comprising the steps of:
moving the build table in a downward direction;
laying a second layer of the powder bed over the bottom slice;
melting at least in-part the second layer, with the energy gun, into at least one second melt pool;
solidifying the at least one second melt pool thereby forming a top slice disposed over the bottom slice; and
sending ultrasonic waves through the bottom and top slices.
8. The method of claim 7 , further comprising moving the sensor array with the build table in the downward direction.
9. The method of claim 1 , further comprising the step of:
detecting a defect in the workpiece.
10. The method of claim 9 , further comprising the step of:
re-melting the top slice to remove the delamination defect.
11. A method of operating an additive manufacturing system, the method comprising the steps of:
forming a first slice of a workpiece with a build table by laying a powder bed in a first layer upon a build table, melting at least in-part the first layer, with an energy gun, into at least one first melt pool, and solidifying the melt pool thereby forming the slice as a bottom slice directly upon the build table, the build table configured to support the powder bed, the build table comprising a top side and a bottom side, the build table further comprising a sheet defining the top side of the build table, the sheet comprising a top face and a bottom face;
forming a second slice of a workpiece by moving the build table in a downward direction, laying a second layer of the powder bed over the bottom slice, melting at least in-part the second layer, with the energy gun, into at least one second melt pool, and solidifying the at least one second melt pool thereby forming a top slice disposed over the bottom slice; and
sending ultrasonic waves through the bottom and top slices with an ultrasonic inspection system, the ultrasonic inspection system comprising a plurality of ultrasonic sensors, the plurality of ultrasonic sensors forming a sensory array integrated into the build table between the top side and the bottom side of the build table.
12. The method of claim 11 , wherein the top face is configured to directly support the bottom slice of a plurality of slices and wherein each sensor of the plurality of sensors includes a buffer in direct contact with the bottom face, each buffer located between a respective transducer of each sensor of the plurality of sensors and the bottom face.
13. The method of claim 12 , further comprising the step of:
detecting a defect in the workpiece.
14. The method of claim 13 , further comprising the step of:
re-melting the top slice to remove the delamination defect.