Sensor fusion for powder bed manufacturing process control

Abstract

A system for additive manufacturing a component includes an additive manufacturing machine for building a component layer by layer and a first sensor configured to collect a first physical property data for each layer of the component as each layer is formed by the additive manufacturing machine. The system also includes a second sensor configured to collect a second physical property data for each layer of the component as each layer is formed by the additive manufacturing machine. A computing device is operatively connected to the first and second sensors and configured to receive the first physical property data and the second physical property data of the component and configured to compare the first physical property data with the second physical property data to determine a potential failure mode in the component.

1 . A system for additive manufacturing a component, the system comprising:
 an additive manufacturing machine for building a component layer by layer;   a first sensor configured to collect a first physical property data for each layer of the component as each layer is formed by the additive manufacturing machine;   a second sensor configured to collect a second physical property data for each layer of the component as each layer is formed by the additive manufacturing machine; and   a computing device operatively connected to the first and second sensors and configured to receive the first physical property data and the second physical property data of the component and configured to compare the first physical property data with the second physical property data to determine a potential failure mode in the component.   
     
     
         2 . The system of  claim 1 , wherein the first sensor is selected from the group consisting of high speed cameras, grayscale optical cameras, thermal cameras, fluid flow detectors, gas analyzers, ultrasonic emitters, and ultrasonic receivers. 
     
     
         3 . The system of  claim 1 , wherein the second sensor is selected from the group consisting of high speed cameras, grayscale optical cameras, thermal cameras, fluid flow detectors, gas analyzers, ultrasonic emitters, and ultrasonic receivers. 
     
     
         4 . The system of  claim 1 , wherein the system further comprises:
 a third sensor configured to collect a third physical property data for each layer of the component.   
     
     
         5 . The system of  claim 1 , wherein the third sensor is selected from the group consisting of high speed cameras, grayscale optical cameras, thermal cameras, fluid flow detectors, gas analyzers, ultrasonic emitters, and ultrasonic receivers.