Abstract: Method of detecting defects in an additively manufactured metal part is disclosed. In some embodiments, methods of detecting defects in an additively manufactured metal part include: additively manufacturing each metal layer of a metal body, capturing one or more images of each metal layer, and processing the images to detect potential defect areas in each metal layer.

Abstract: Methods for creating three-dimensional volume quality models of additively manufactured metal bodies are disclosed. In one embodiment, a method comprises additively manufacturing each metal layer of a metal body. One or more images of the first metal layer are obtained. The image(s) are processed to detect and map potential manufacturing defects in the first metal layer. A two-dimensional contour of the first metal layer is generated from the three-dimensional CAD model. The mapped defects are integrated into the two-dimensional contour. A first layer of a three-dimensional volume quality model of the metal body is created based on the integrated two-dimensional contour.

Abstract: In some embodiments of the instant disclosure, a method is provided comprising: additively manufacturing a part via a material deposition-based additive manufacturing technique; concomitant with additively manufacturing the part, measuring a z-height of the deposition via a non-linear mathematical model to determine a measured z-height, wherein the measured z-height is a distance between an additive manufacturing system energy source and a top surface of a molten pool; comparing the measured z-height with a target z-height to identify a difference between the measured z-height and the target z-height; adjusting a motion controller to set a corrected z-height; and depositing an additive manufacturing feed material based on the corrected z-height.

Abstract: An apparatus and method for measuring broken spot weld artifacts has a framework for supporting a light and a plurality of cameras for acquiring controlled images of a specimen with minimal distortion and parallax. The framework holds the specimen flat and in a reproducible position, controlling movement while imaging. The image data is received in a computer programmed with image processing software capable of isolating and measuring the artifacts. A calibration standard is used to correct for aberrations.

Abstract: Methods for creating three-dimensional volume quality models of additively manufactured metal bodies are disclosed. In one embodiment, a method comprises additively manufacturing each metal layer of a metal body. One or more images of the first metal layer are obtained. The image(s) are processed to detect and map potential manufacturing defects in the first metal layer. A two-dimensional contour of the first metal layer is generated from the three-dimensional CAD model. The mapped defects are integrated into the two-dimensional contour. A first layer of a three-dimensional volume quality model of the metal body is created based on the integrated two-dimensional contour.

Abstract: An apparatus and method for measuring broken spot weld artifacts has a framework for supporting a light and a plurality of cameras for acquiring controlled images of a specimen with minimal distortion and parallax. The framework holds the specimen flat and in a reproducible position, controlling movement while imaging. The image data is received in a computer programmed with image processing software capable of isolating and measuring the artifacts. A calibration standard is used to correct for aberrations.

Abstract: A system for rolling metal sheet having a substantially uniform flatness including a rolling mill including a pair of work rollers for reducing the thickness of a metal sheet, an induction heating apparatus in close proximity to at least one roller, bending jacks corresponding to each of the rollers, and a cooling spray system in proximity to rollers; a flatness measuring device positioned to measure a differential in flatness of the metal sheet; and an mill control interface connected between the flatness measuring device and the rolling mill's actuators, in which the mill control interface is configured to actuate the induction heating apparatus, the bending jacks and the cooling spray system to substantially eliminate flatness differentials is the metal sheet's flatness. The induction coil heating apparatus is configured to eliminate high tension on the strip edges caused by the temperature gradients in the work rolls at the edges of the metal strip.

Abstract: A high bandwidth vapor density diagnostic system for measuring the density of an atomic vapor during one or more photoionization events. The system translates the measurements from a low frequency region to a high frequency, relatively noise-free region in the spectrum to provide improved signal to noise ratio.

Abstract: A heterodyne laser instantaneous frequency measurement system is disclosed. The system utilizes heterodyning of a pulsed laser beam with a continuous wave laser beam to form a beat signal. The beat signal is processed by a controller or computer which determines both the average frequency of the laser pulse and any changes or chirp of the frequency during the pulse.

Abstract: The heterodyne laser diagnostic system includes, in one embodiment, an average power pulsed laser optical spectrum analyzer for determining the average power of the pulsed laser. In another embodiment, the system includes a pulsed laser instantaneous optical frequency measurement for determining the instantaneous optical frequency of the pulsed laser.

Abstract: A heterodyne laser instantaneous frequency measurement system is disclosed. The system utilizes heterodyning of a pulsed laser beam with a continuous wave laser beam to form a beat signal. The beat signal is processed by a controller or computer which determines both the average frequency of the laser pulse and any changes or chirp of th frequency during the pulse.