US 11,867,638 B2
System and method for in situ inspection of defects in additively manufactured parts using high speed melt pool pyrometry
Jean-Baptiste Forien, Livermore, CA (US); Nicholas P. Calta, San Jose, CA (US); Gabriel Mark Guss, Manteca, CA (US); and Manyalibo Joseph Matthews, Livermore, CA (US)
Assigned to Lawrence Livermore National Security, LLC, Livermore, CA (US)
Filed by Lawrence Livermore National Security, LLC, Livermore, CA (US)
Filed on Oct. 28, 2020, as Appl. No. 17/082,855.
Prior Publication US 2022/0128483 A1, Apr. 28, 2022
Int. Cl. G01N 21/88 (2006.01); G01N 21/95 (2006.01); B29C 64/386 (2017.01); B22F 10/80 (2021.01); B33Y 50/00 (2015.01)
CPC G01N 21/8806 (2013.01) [B22F 10/80 (2021.01); B29C 64/386 (2017.08); B33Y 50/00 (2014.12); G01N 21/95 (2013.01); G01N 2201/06113 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A system for detecting anomalies in additively manufactured microlattice parts involving struts, the system comprising:
an energy source configured to generate a beam of energy for creating a melt pool in a layer of feedstock material being selectively fused to make a part in an additive manufacturing operation;
an optical sensor configured to receive a thermal emission signal reflected from the melt pool which is indicative of a temperature of the melt pool formed from the feedstock material at a known location on a layer of the feedstock material, while the feedstock material is in a process of being melted and being fused at the known location; and
a controller responsive to the optical sensor and configured to receive and analyze data relating to an intensity of the received thermal emission signal over a selected period of time, where the selected period of time depends on a size of the strut being created, to determine if an anomaly exists at the known location, the received thermal emission signal relating to obtained temperature values at the known location;
the controller using the obtained temperature values to generate a statistical prediction if the part is being built as designed or if the part is defective; and
wherein the received thermal emission signal travels co-axially with the energy beam for at least a portion of a length of travel of the energy beam.