Systems and methods for additive manufacturing operations
This disclosure describes various system and methods for monitoring photons emitted by a heat source of an additive manufacturing device. Sensor data recorded while monitoring the photons can be used to predict metallurgical, mechanical and geometrical properties of a part produced during an additive manufacturing operation. In some embodiments, a test pattern can be used to calibrate an additive manufacturing device.
1. A method for operating an additive manufacturing system, the method comprising:
controlling an energy beam of the additive manufacturing system to scan across a build region of a powder bed using a plurality of discrete scan paths, wherein each discrete scan path has a respective path length;
detecting photons emitted from the build region of the powder bed during each discrete scan path using an optical sensor that generates corresponding sensor data;
determining an average intensity of each discrete scan path using the sensor data;
generating a relationship between the average intensity of each discrete scan path and a length of each corresponding discrete scan path; and
comparing the relationship to a baseline relationship.
2. The method of claim 1 , further comprising changing an operating parameter of the additive manufacturing system in response to the comparing.
3. The method of claim 1 , further comprising calibrating the additive manufacturing system in response to the comparing.
4. The method of claim 1 , wherein the relationship includes a best fit line.
5. The method of claim 1 , wherein the plurality of discrete scan paths are related to a single layer of a part.
6. The method of claim 1 , wherein the plurality of discrete scan paths include all discrete scan paths for a part.
7. The method of claim 1 , wherein the length of each corresponding discrete scan path is derived from the sensor data.
8. The method of claim 1 , wherein the baseline relationship includes an average intensity of a plurality of discrete scan paths and a length of each corresponding discrete scan paths.
9. The method of claim 1 , wherein the baseline relationship is derived from manufacturing a part on the additive manufacturing system.
10. The method of claim 1 , wherein the additive manufacturing system is a first additive manufacturing system, and wherein the baseline relationship is derived from manufacturing a part on a second additive manufacturing system.
11. A method for operating a manufacturing system, the method comprising:
depositing a layer of powder on a build region of a powder bed;
fusing at least a portion of the layer of powder to form a layer of a part by moving a laser beam of the manufacturing system across the build region in plurality of discrete scan paths, wherein each discrete scan path has a respective path length;
detecting photons emitted from the build region of the powder bed during each discrete scan path using a sensor that generates corresponding sensor data;
determining an average intensity for each discrete scan path using the sensor data;
generating a correlation between the average intensity of each discrete scan path and a length of each corresponding discrete scan path; and
comparing the correlation to a baseline correlation.
12. The method of claim 11 , further comprising changing an operating parameter of the manufacturing system in response to the comparing.
13. The method of claim 11 , further comprising calibrating the manufacturing system in response to the comparing.
14. The method of claim 11 , wherein the correlation includes a best fit line between the average intensity of each discrete scan path and the length of each corresponding discrete scan path.
15. The method of claim 11 , wherein the length of each corresponding discrete scan path is derived from the sensor data.
16. The method of claim 11 , wherein the baseline correlation includes an average intensity of a plurality of discrete scan paths and a length of each corresponding discrete scan paths for a layer of a part.
17. The method of claim 11 , wherein the manufacturing system is a first additive manufacturing system, and wherein the baseline correlation is derived from manufacturing a layer of a part on a second additive manufacturing system.
18. An additive manufacturing system comprising:
a powder bed including a mechanism arranged to spread a layer of powder across a build region of the powder bed;
an energy source configured to fuse at least a portion of the layer of powder to form a layer of a part, wherein a beam from the energy source is moved across the build region of the powder bed in a plurality of discrete scan paths, and wherein each discrete path has a respective path length;
a sensor arranged to receive data from a region encompassing the powder bed; and
a computing system configured to:
receive data from the sensor during each discrete scan path;
determine an intensity for each discrete scan path;
generate a correlation between the intensity for each discrete scan path and a length of each corresponding discrete scan path; and
compare the correlation to a baseline correlation.
19. The additive manufacturing system of claim 18 , wherein the computer system is further configured to determine an average intensity for each discrete scan path.
20. The additive manufacturing system of claim 18 , wherein the baseline correlation is for a layer of the part formed on the additive manufacturing system.