Granted Patent B2

US 12,293,527 · App. 17/932,962 · Granted May 6, 2025

Inventors: Scott Nelson (Indianapolis, IN); Baily Thomas (Rogersville, MO); Abdalla R. Nassar (State College, PA); Jason Scherer (State College, PA); John Grubbs (Indianapolis, IN)

Assignee: Rolls-Royce Corporation

G06T7/20B22F10/80B22F12/90B33Y50/00G06T7/62G06T7/70G06T11/00G06T2207/10016

Abstract

Claims (66)

1. A powder flow monitoring system configured to monitor a powder stream during a blown powder additive manufacturing process, wherein the blown powder additive manufacturing process includes adding material via a powder delivery device to a build surface of a component in sequential layers, wherein the blown powder additive manufacturing process forms a final component composed of the sequential layers on the build surface, the powder flow monitoring system comprising:

an illumination device configured to illuminate at least some of the powder stream between the powder delivery device and the build surface of the component, wherein the powder delivery device defines a longitudinal axis oriented toward the build surface;

an imaging device configured to image the illuminated powder at an image plane between the powder delivery device and the build surface of the component to generate image data, the imaging device being positioned adjacent to the longitudinal axis; and

one or more computing devices configured to, during the blown powder additive manufacturing process:

receive the image data representing the illuminated powder of the powder stream between the powder delivery device and the build surface of the component;

generate a representation of the powder stream based on the image data; and

output the representation of the powder stream for display at a display device.

2. The powder flow monitoring system of claim 1 , wherein the imaging device is configured to capture a sequence of images, wherein the one or more computing devices is further configured to:

receive image data representative of the sequence of images; and

generate the representation of the powder stream based on the sequence of images.

3. The powder flow monitoring system of claim 1 , wherein the one or more computing devices is configured to generate the representation by at least:

determining powder locations within the image plane.

4. The powder flow monitoring system of claim 3 , wherein the one or more computing devices is configured to determine powder locations within the image plane with reference to a polar coordinate system.

5. The powder flow monitoring system of claim 3 , wherein the one or more computing devices is configured to generate the representation by at least:

selecting at least one radius within the image plane; and

determining a radial distance along the at least one radius at which a mean intensity of the powder locations occurs.

6. The powder flow monitoring system of claim 3 , wherein the one or more computing devices is configured to generate the representation by at least:

selecting a quadrant within the image plane; and

determining a radial distance within the quadrant at which a mean intensity of the powder locations occurs.

7. The powder flow monitoring system of claim 1 , wherein the one or more computing devices is configured to generate the representation by at least:

determining a powder mass flow based on the imaged powder.

8. The powder flow monitoring system of claim 7 , wherein the one or more computing devices is configured to determine a powder mass flow based on the imaged powder using a calibration curve relating powder mass flow to particle detections.

9. The powder flow monitoring system of claim 1 , wherein the one or more computing devices is configured to generate the representation by at least:

selecting a region of interest within the image plane;

summing all detections of powder at the image plane over time; and

outputting a heat map of detections as a function of location within the image plane.

10. The powder flow monitoring system of claim 1 , wherein the one or more computing devices is configured to generate the representation by at least:

selecting a region of interest within the image plane; and

generating a plot of detections versus time for the region of interest.

11. The powder flow monitoring system of claim 1 , wherein the one or more computing devices is configured to generate the representation by at least:

selecting a region of interest within the image plane;

determining a radial distance within the region of interest at which a mean intensity of powder locations occurs;

determining a standard deviation of the radial distance; and

generating a plot illustrating the radial distance and the standard deviation of the radial distance for the region of interest versus time.

12. A method comprising:

additively manufacturing a component via a blown powder additive manufacturing process, wherein the blown powder additive manufacturing process includes adding material via a powder delivery device to a build surface of the component in sequential layers, and wherein the blown powder additive manufacturing process forms a final component composed of the sequential layers on the build surface; and

monitoring a powder stream during the blown powder additive manufacturing process by at least:

illuminating, by an illumination device, at least some of the powder stream between the powder delivery device and the build surface of the component;

imaging, by an imaging device, the illuminated powder at an image plane between the powder delivery device and the build surface of the component to generate image data;

receiving, by one or more computing devices, the image data representing illuminated powder of the powder stream between the powder delivery device and the build surface of the component;

generating, by the one or more computing devices, a representation of the powder stream based on the imaged powder; and

outputting, by the one or more computing devices, the representation of the powder stream for display at a display device.

13. The method of claim 12 , wherein:

the imaging device is configured to capture a sequence of images;

receiving the image data comprises receiving, by the one or more computing devices, image data representative of the sequence of images; and

generating the representation of the powder stream comprises generating, by the one or more computing devices, the representation of the powder stream based on the sequence of images.

14. The method of claim 12 , wherein generating the representation of the powder stream based on the imaged powder comprises determining, by the one or more computing devices, powder locations within the image plane.

15. The method of claim 14 , wherein the one or more computing devices determines powder locations within the image plane with reference to a polar coordinate system.

16. The method of claim 14 , wherein generating the representation of the powder stream based on the imaged powder comprises:

selecting, by the one or more computing devices, at least one radius within the image plane; and

determining, by the one or more computing devices, a radial distance along the at least one radius at which a mean intensity of the powder locations occurs.

17. The method of claim 14 , wherein generating the representation of the powder stream based on the imaged powder comprises:

selecting, by the one or more computing devices, a quadrant within the image plane; and

determining, by the one or more computing devices, radial distance within the quadrant at which a mean intensity of the powder locations occurs.

18. The method of claim 12 , wherein generating the representation of the powder stream based on the imaged powder comprises:

determining, by the one or more computing devices, a powder mass flow based on the imaged powder.

19. The method of claim 12 , wherein monitoring the powder stream during the blown powder additive manufacturing process further includes outputting, by the one or more computing devices, a control signal to control the blown powder additive manufacturing process based on the representation of the powder stream.

20. An additive manufacturing system, comprising:

a powder delivery device configured to direct a powder stream toward a build surface of a component during a blown powder additive manufacturing process, wherein the powder delivery device defines a longitudinal axis oriented toward the build surface, and wherein the blown powder additive manufacturing process forms a final component composed of sequential layers on the build surface; and

a powder flow monitoring system configured to monitor the powder stream during the blown powder additive manufacturing process, the powder flow monitoring system comprising:

an illumination device configured to illuminate at least some of the powder stream between the powder delivery device and the build surface of the component, wherein the powder delivery device defines a longitudinal axis oriented toward the build surface;

an imaging device configured to image the illuminated powder at an image plane between the powder delivery device and the build surface of the component to generate image data, the imaging device being positioned adjacent to the longitudinal axis; and

one or more computing devices configured to, during the blown powder additive manufacturing process:

receive the image data representing the illuminated powder of the powder stream between the powder delivery device and the build surface of the component;

generate a representation of the powder stream based on the image data; and

output the representation of the powder stream for display at a display device.

Assignments (1)

Continuity (2)

References Cited (34)