Additive manufacturing with photo-acoustic tomography defect testing
AssigneeSeurat Technologies, Inc.
InventorsFrancis L. Leard, James A. DeMuth, Andrew J. Bayramian
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Abstract
An additive manufacturing method supporting layer by layer testing includes a layer test including generating a hammer beam using laser light having a first wavelength, generating a read-out beam using laser light having a second wavelength, directing the generated hammer beam toward a first layer on a part to provide an acoustic hammer pulse that induces surface movement of the part, and reading the surface movement of the part using the read-out beam directed to a second position on the part. Layers can be added and the layer test repeated.
Claims14
An additive manufacturing method comprising:
- conducting a layer test on a part comprising one or more layers, the layer test comprising:
- generating a two-dimensional patterned beam comprising a hammer channel having a first wavelength and a plurality of read-out channels having a second wavelength;
- directing the two-dimensional patterned beam toward a layer on the part to provide an acoustic hammer pulse using the hammer channel to induce surface movement of the part, and
- reading a response to the plurality of read-out channels based on the surface movement of the part;
- adding a layer to the part by performing a corrective action based on the response;
- and
- repeating the layer test.
An additive manufacturing system, comprising:
- an addressable light patterning unit to receive a light beam and emit light as a two-dimensional patterned beam;
- a laser ultrasonic imaging system (LUIS) that generates a hammer beam having a first wavelength and a plurality of read-out beams having a second wavelength, wherein the hammer beam and the read-out beams are arranged in a two-dimensional pattern;
- and
- an image relay to receive the two-dimensional patterned beam and focus it as a two-dimensional image on a part being additively manufactured on a powder bed and to relay a response to the plurality of read-out beams to an interferometer, the response generated based on surface movement of the part induced by the hammer beam.
An additive manufacturing system, comprising:
- a beam patterning unit to generate a first two-dimensional patterned laser beam from a laser beam;
- a plurality of beam switching units to direct two-dimensional patterned energy beams;
- a plurality of beam steering units to receive and direct the first two-dimensional patterned laser beam;
- a laser ultrasonic imaging system (LUIS) that generates a hammer beam using laser light having a first wavelength and a read-out beam using laser light having a second wavelength
- at least one powder bed to receive at least a portion of the directed two-dimensional patterned laser beam from at least one of the plurality of energy steering units and also receive a second two-dimensional pattern laser beam comprising a hammer channel based on the generated hammer beam and a plurality of read-out channels based on the generated read-out beam,
- wherein the hammer channel is configured to induce a surface movement at a part being additively manufactured at the powder bed and the plurality of read-out channels is configured to generate a response from the part based on the induced surface movement.
An additive manufacturing system, comprising:
- an additive writing system capable of forming a part;
- and
- a laser ultrasonic imaging system (LUIS) that generates a two-dimensional patterned beam comprising a hammer channel having a first wavelength and a plurality of read-out channels having a second wavelength, the two-dimensional patterned beam being directed against the part,
- wherein the hammer channel is configured to induce a surface movement at the part and the plurality of read-out channels is configured to generate a response from the part based on the induced surface movement.
Dependencies are inferred from the claim text.