Device and method for additive welding of metal articles
The rotating laser beam method with coaxial filler feed and standard optics addresses the challenges of electron beam and laser cladding, achieving high-quality, efficient, and cost-effective metal surfacing with reduced thermal stress and improved material compatibility.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- OBSHCHESTVO S OGRANICHENNOJ OTVETSTVENNOSTYU IKSVELD
- Filing Date
- 2024-12-23
- Publication Date
- 2026-06-25
AI Technical Summary
Existing methods for additive surfacing of metals using electron beams and laser cladding face challenges such as high vacuum requirements, increased costs, personnel safety concerns, limited material range, non-uniform energy distribution, and complex designs due to high voltage and X-ray radiation, as well as thermal stress and precise alignment issues with axicon optics.
A method and device utilizing a rotating laser beam that describes the lateral surface of a cone during rotation, with coaxial filler material feed, oscillating laser trajectory, and optional inert gas environment, combined with standard optical components and pulsed filler material supply, to improve bead formation stability and reduce heat input.
This approach reduces thermal load on optical elements, ensures uniform heating, extends service intervals, and enhances manufacturing efficiency by using standard components, allowing for high-quality surfacing with a wider material range and reduced maintenance.
Smart Images
Figure RU2024000387_25062026_PF_FP_ABST
Abstract
Description
[0001] Device and method for additive surfacing of metal products
[0002] AREA OF TECHNOLOGY
[0003] The invention relates to the field of laser processing of materials and can be used in laser surfacing, in particular to a device and method for additive surfacing of metal products using a rotating laser beam, which describes the lateral surface of a cone during rotation, with a coaxial feed of filler material relative to the laser beam.
[0004] LEVEL OF TECHNOLOGY
[0005] A method for electron beam surfacing of metal and a device for implementing the same are known, disclosed in CN 106392290 A, published 02 / 15 / 2017. The method for surfacing with concentrated energy sources in the form of multiple electron beams with a vertical feed of filler wire consists of performing electron beam surfacing or welding with a symmetrical arrangement of 2, 3 or 4 electron beam guns around a channel for feeding filler wire.
[0006] A disadvantage of the technical solution described above is that the use of electron beam equipment requires a high vacuum, which increases the cost of the equipment and process and leads to difficulties in handling powder materials. Furthermore, the use of high voltage and X-ray radiation increases personnel safety requirements, limits the range of materials used in the equipment, and complicates the design. Furthermore, the use of multiple beams does not ensure a completely uniform energy distribution around the feed filler material.
[0007] The prior art also includes a method and device for producing three-dimensional objects, disclosed in US 10695835 B2, published June 30, 2020.The device comprises a base substrate placed on a support plate, an electron beam gun, feed means for feeding the source material into the melting zone, a positioning system for positioning said support plate with the base substrate, a vacuum-tight working chamber in which the energy source for creating a molten bath on the substrate and for melting the source material in said system is a gas-discharge electron beam gun with a cold ring cathode placed between two round anode electrodes placed coaxially to said cathode which generates an electron beam in the form of a hollow inverted cone, and a guide for feeding the filler material is placed along the axis of said electron beam gun, and said gas-discharge electron beam gun and said guide for the raw material are combined into a single functional unit.A disadvantage of the technical solution described above is that the use of electron beam equipment requires a high vacuum, which increases the cost of the equipment and process and leads to difficulties in handling powdered materials. Furthermore, the use of high voltage and X-ray radiation increases personnel safety requirements, limits the range of materials used in the equipment, and complicates the design.
[0008] The prior art also includes a method and device for laser cladding, disclosed in RU 2580180 C2, published 10.04.2016. The method consists of feeding the cladding material into the focal region of a laser beam located on the surface of the workpiece. A series of parallel annular laser beams are formed from the initial circular laser beam, converted into a series of conical beams and separately focused along a single optical axis along which the cladding material is fed. The device comprises a laser optically coupled to a conical beam formation system, a focusing lens and a cladding material feed system, an optical system for forming a series of annular laser beams with adjustable distribution of laser radiation power across the annular beams, a rotating mirror with an opening for passing tubes for feeding gas, coolant and cladding material, and a system of focusing conical mirrors.
[0009] A disadvantage of the technical solution described above is the use of a multi-axicon, a complex and expensive optical element. When laser radiation hits the tip of its central element, it induces significant thermal stress on the axicon. Furthermore, the design requires very precise alignment of the laser beam relative to the tip of its central element. This method does not allow for operation in a vacuum. Control of heat distribution between the wire and the deposited base is achieved by introducing an additional lens and cannot be adjusted directly during the process.
[0010] DISCLOSURE OF THE INVENTION
[0011] The objective of the claimed invention is to develop an improvement in the stability of the quality of bead formation during additive surfacing of metals using laser radiation.
[0012] The technical result of the invention is a reduction in heat input during surfacing, an increase in the quality of surfacing, manufacturability and the service interval of optical elements.
[0013] The specified technical result is achieved due to the fact that the method of additive surfacing of metal products includes feeding filler material with the help of a guide channel into the surfacing area, in which the filler material is melted by a rotating laser beam, which describes during rotation the lateral surface of a cone, which is formed by converting a rotating laser beam, which describes during rotation the lateral surface of a cylinder, and formed from the original laser beam, wherein the feed of filler material into the surfacing area is carried out coaxially relative to the cone described by the rotating laser beam.
[0014] The melting of the filler material is carried out in a vacuum or in an inert gas environment, and, if necessary, an additional supply of inert gas is carried out into the surfacing area (the area of the laser head nozzle) or through a guide channel.
[0015] The original laser beam, before being converted into a rotating laser beam that describes the lateral surface of the cylinder during rotation, is subjected to oscillation along a trajectory that ensures an increase in the area of interaction of the laser beam with the base of the metal product.
[0016] Wire or powder is used as filler material.
[0017] The trajectory of the rotating laser beam, which describes the lateral surface of the cylinder during rotation, intersects the guide channel and its fastening elements, and at the moment of intersection of the said laser beam of the guide channel and its fastening elements, the power of the laser radiation is reduced.
[0018] The trajectory of the rotating laser beam, which describes the lateral surface of the cylinder during rotation, goes around the guide channel, for which a system of mirrors or prisms is additionally used.
[0019] Additionally, a second source laser beam is formed, wherein the first laser beam emits an infrared spectrum, and the second source laser beam emits green or blue spectra of visible light.
[0020] The filler wire is fed into the welding area after it has been preheated resistively by passing direct or alternating current through it.
[0021] The filler material is fed into the welding area vertically or at an angle.
[0022] A device for additive surfacing of metal articles comprising a filler material feed unit and a sequentially arranged unit for generating an initial laser beam, made from a laser radiation source and a laser beam expander, a unit for generating a rotating laser beam, which describes the lateral surface of a cylinder during rotation, in the form of a system of rotating mirrors, a unit for generating a rotating laser beam, which describes the lateral surface of a cone during rotation, wherein the guide channel of the filler material feed unit is located coaxially with the cone described by the laser beam. The device is additionally equipped with at least one rotating mirror, located after the unit for generating the rotating laser beam, which describes the lateral surface of the cylinder during rotation.
[0023] The unit for forming a rotating laser beam, which describes the lateral surface of a cone during rotation, is made in the form of a sequentially located focusing lens and protective glass.
[0024] The unit for forming a rotating laser beam, which describes the lateral surface of a cone during rotation, is made in the form of a sequentially arranged rotating platform with a mirror, a system of rotating mirrors rotating synchronously with the mirrors, and protective glass.
[0025] The unit for forming a rotating laser beam, which describes the lateral surface of the cone during rotation, is additionally equipped with a diaphragm that rotates synchronously with the mirrors of the rotating mirror system.
[0026] In the case of using a rotating mirror in the device, the guide channel of the filler material supply unit, passing through the unit for forming a rotating laser beam, which describes the side surface of the cylinder during rotation, into the surfacing area, is introduced into the cavity of the laser beam, which describes the side surface of the cylinder during rotation, vertically from above through the opening of the rotating mirror, located between the unit for forming a conical laser beam and the system of rotating mirrors.
[0027] The guide channel of the filler material feed unit is inserted into the cavity of the laser beam, which, when rotating, describes the side surface of the cylinder, from the side or from above.
[0028] The guide channel of the filler material feed unit is directed towards the welding area vertically or at an angle of no more than 30°.
[0029] BRIEF DESCRIPTION OF DRAWINGS
[0030] The invention will be better understood from the description, which is not limiting in nature and is given with reference to the accompanying drawings, which show:
[0031] Fig. 1 - The claimed device with a lateral feed of filler material, containing a focusing lens.
[0032] Fig. 2 - The claimed device with vertical feed of filler material, containing a focusing lens.
[0033] Fig. 3 - The claimed device with a lateral feed of filler material, containing a focusing lens protected from the welding area by a diaphragm.
[0034] Fig. 4 - The claimed device with a side feed of filler material, containing a rotating platform with a mirror for creating a focusing laser beam. 1 - laser beam; 2 - laser beam expander; 3 - system of rotating mirrors; 4 - rotating mirror; 5 - laser beam describing the side surface of the cylinder during rotation; 6 - focusing lens; 7 - rotating laser beam describing the side surface of the cone during rotation; 8 - guide channel; 9 - tip; 10 - protective glass; 11 - surfacing area; 12 - rotating mirror; 13 - rotating diaphragm; 14 - rotating platform with mirror; 15 - laser radiation source; 16 - metal product.
[0035] IMPLEMENTATION OF THE INVENTION
[0036] The device for additive surfacing of metal products comprises a filler material supply unit made from a filler material supply mechanism and a guide channel (8) with a tip (9), and a sequentially arranged unit for forming an initial laser beam (1), made from a source (15) of laser radiation and an expander (2) of a laser beam (1), a unit (3) for forming a rotating laser beam (5), describing the side surface of a cylinder during rotation, in the form of a system of rotating mirrors, a unit for forming a rotating laser beam (7), describing the side surface of a cone during rotation, wherein the guide channel (8) of the filler material supply unit is located coaxially to the cone described by the laser beam (7).
[0037] The device is additionally equipped with at least one rotating mirror (4) located after the unit (3) for forming a rotating laser beam (5), which describes the side surface of the cylinder during rotation.
[0038] The unit for forming a rotating laser beam (7), which describes the lateral surface of a cone during rotation, is made in the form of a sequentially located focusing lens (6) and protective glass (10).
[0039] The unit for generating a rotating laser beam (7), which describes the lateral surface of a cone during rotation, is designed in the form of a sequentially arranged rotating platform (14) with a mirror, a rotating mirror system (3) rotating synchronously with the mirrors, and a protective glass (10). The mirror in the rotating platform (14) is located remotely from the center of the platform (14) and, together with the platform, rotates in a circle relative to the central axis of the platform.
[0040] The unit for forming a rotating laser beam (7), which describes the lateral surface of the cone during rotation, is additionally equipped with a diaphragm (13), rotating synchronously with the mirrors of the rotating mirror system (3).
[0041] In the case of using a rotating mirror (4) in the device, the guide channel (8) of the filler material supply unit, passing through the unit for forming a rotating laser beam (5), which describes the side surface of the cylinder during rotation, into the surfacing area, is introduced into the cavity of the laser beam (5), which describes the side surface of the cylinder during rotation, vertically from above through the opening of the rotating mirror (4), located after the unit (3) for forming a rotating laser beam (5), which describes the side surface of the cylinder during rotation.
[0042] The guide channel (8) of the filler material feed unit is inserted into the cavity of the laser beam (5), which, when rotating, describes the side surface of the cylinder, from the side or from above.
[0043] The guide channel (8) of the filler material supply unit is directed towards the surfacing area (1) vertically or at an angle of no more than 30°.
[0044] The claimed method using the claimed device is carried out as follows.
[0045] The laser beam (1) generated in the source (15) of laser radiation enters the expander (2) of the laser beam (1), where it is expanded. After which the laser beam (1) enters the unit (3) for generating a rotating laser beam (5), which describes the lateral surface of a cylinder during rotation, in the form of a system of rotating mirrors, which is a platform with two mirrors fixed to it, wherein the first mirror is fixed in the center of the platform and rotates together with the platform around the central axis of the platform, and the second mirror is fixed on the platform at a certain distance (depending on the required width of the circle described by the laser beam) from the first mirror, wherein the second mirror rotates together with the platform around the central axis in a circle relative to the central axis of the platform.Then, from the unit (3), the rotating laser beam (5), describing the lateral surface of the cylinder during rotation, enters the unit for forming the rotating laser beam (7), describing the lateral surface of the cone during rotation, in the form of a focusing lens (6), after which the formed rotating laser beam (7), describing the lateral surface of the cone during rotation, passes the protective glass intended for protecting the optics from splashes and evaporation products, the output of the laser beam (7) into the surfacing area (11), and is focused in the surfacing area (11) on the surface of the metal product (16). The filler material - filler wire, entering through the tip (9) of the guide channel (8) into the surfacing area (11), is melted by the laser beam (7), as a result of which the wire material is transferred to the surface of the metal product (16).
[0046] Before being converted into a rotating laser beam that traces the side surface of the cylinder, the original laser beam is oscillated along a trajectory that increases the area of interaction between the laser beam and the base metal part. Conductive powder and various metal alloy powders (12Kh18N10T, VT6, etc.) with a particle size of 80-120 µm or 120-200 µm are also used as filler material.
[0047] In the case of lateral feed of filler material, the trajectory of the rotating laser beam (5), describing the lateral surface of the cylinder during rotation, intersects the guide channel (8), and at the moment of intersection of the said laser beam (5) of the guide channel (8) and the elements of its fastening, the power of the laser radiation is reduced.
[0048] In the case of lateral feed of filler material, the trajectory of the rotating laser beam (5), which describes the lateral surface of the cylinder during rotation, goes around the guide channel (8), for which a system of mirrors or prisms is additionally used.
[0049] Additionally, a second initial laser beam (1) is formed, wherein the first laser beam (1) emits an infrared radiation spectrum (0.74-1000 μm), and the second initial laser beam (1) emits green (500-565 nm) or blue (440-485 nm) visible light spectra.
[0050] In the case of using filler material in the form of filler wire, it is fed into the welding area with preliminary resistive heating by passing direct or alternating current through it.
[0051] The filler material is fed into the welding area vertically or at an angle of no more than 30°.
[0052] The claimed technical solution allows for pulsed feeding of filler material, namely: reciprocating feeding of filler material, alternating feeding and stopping of filler material feeding, or alternating feeding of filler material and feeding of filler material at a reduced speed.
[0053] The pulsed supply of filler material is carried out using a binary feedback signal, which indicates the presence of contact between the wire and the base of the metal product or its absence based on the registration of an electrical contact or registration of contact by other methods.
[0054] With pulsed wire feed, the laser radiation power changes according to a given law synchronously with the change in wire feed speed.
[0055] A rotating platform with mirrors is fixed on a motor with a hollow shaft, through the opening of which a laser beam (1) of a laser radiation source (15) is fed to a system of rotating mirrors.
[0056] Compared to a standard laser beam, cladding with a rotating cone-shaped laser beam distributes energy over a larger area. This reduces the thermal load (thermal power per unit area, i.e., heat flux) on the optical elements, which in turn reduces the risk of lens overheating. Furthermore, dust buildup on a large glass surface also takes longer. Localized splashes and other contaminants that fall on the glass will not significantly reduce its transmission capacity due to the larger area over which the beam is distributed. Furthermore, there is no axicon, the tip of which is subjected to high thermal load due to the concentrated laser beam. This improves the quality of the cladding and extends the service intervals of the optical elements.
[0057] Surfacing with a laser beam that describes the lateral surface of a cone during rotation, compared to a standard laser beam, eliminates the presence of shadowed areas, which allows for more uniform and more targeted heating during surfacing, and therefore reduces heat input.
[0058] Coaxial supply of filler material to the welding area allows to increase the technological efficiency of the process; the filler material is supplied vertically and the welding process is symmetrical relative to the welding direction in the x,y plane, due to the symmetry of the heat source relative to the filler material.
[0059] The use of standard, commercially available laser components (mirrors and lenses), without the use of rare and expensive, large-diameter, high-power axicons, and the elimination of precise laser input adjustment (as with axicons), improves the manufacturing process.
[0060] High quality of surfacing, reduction of heat input and service intervals are also achieved through degassing of the surfacing material, by directing it in a vacuum or inert gas environment, or by additionally supplying inert gas to the surfacing area, by reducing dusting of the optical lens by evaporation products formed in the surfacing area.
[0061] For additional protection of optics from splashes and evaporation products, protective glass and / or diaphragms are used, the walls of which absorb the evaporation products.
[0062] The claimed invention additionally allows:
[0063] - reduce the cost of components used in the production of the laser head;
[0064] - improve the technological efficiency of laser head manufacturing;
[0065] - increase the service life of optical elements due to their lower load;
[0066] - use standard, widely available components in the manufacture of the device to implement the method; - implement simple and adjustable control of the heating zone width and the distribution of heat input between the substrate and the wire directly during the surfacing process;
[0067] - use a wide range of applied materials; - achieve high quality surfacing due to degassing of the surfacing material;
[0068] - ensure a high resource of optical elements and an extended service life of the laser head without its maintenance.
[0069] The invention has been disclosed above with reference to a specific embodiment. Other embodiments of the invention may be apparent to those skilled in the art without altering its essence as disclosed herein. Accordingly, the invention should be considered limited in scope only by the following claims.
Claims
CLAUSES OF THE INVENTION 1. A method for additive surfacing of metal products, which includes feeding filler material using a guide channel into the surfacing area, in which the filler material is melted by a rotating laser beam, which describes during rotation the lateral surface of a cone, which is formed by converting a rotating laser beam, which describes during rotation the lateral surface of a cylinder, and formed from the original laser beam, wherein the feed of filler material into the surfacing area is carried out coaxially relative to the cone described by the rotating laser beam.
2. The method according to paragraph 1, characterized in that the melting of the filler material is carried out in a vacuum or in an inert gas environment.
3. The method according to paragraph 2, characterized in that an inert gas is additionally supplied to the welding area.
4. The method according to paragraph 1, characterized in that the original laser beam, before being converted into a rotating laser beam that describes the side surface of the cylinder during rotation, is subjected to oscillation along a trajectory that ensures an increase in the area of interaction of the laser beam with the base of the metal product.
5. The method according to paragraph 1, characterized in that wire or powder is used as the filler material.
6. The method according to paragraph 1, characterized in that the trajectory of the rotating laser beam, describing the side surface of the cylinder during rotation, intersects the guide channel, and at the moment of intersection of the said laser beam of the guide channel and the elements of its fastening, the power of the laser radiation is reduced.
7. The method according to paragraph 1, characterized in that the trajectory of the rotating laser beam, describing the lateral surface of the cylinder during rotation, goes around the guide channel, for which purpose a system of mirrors or prisms is additionally used.
8. The method according to claim 1, characterized in that a second initial laser beam is additionally formed, wherein the first laser beam emits a spectrum of infrared radiation, and the second initial laser beam emits a green or blue spectrum of visible light.
9. The method according to paragraph 1, characterized in that the filler wire is fed into the surfacing area with its preliminary resistive heating by passing direct or alternating current through it.
10. The method according to paragraph 1, characterized in that the filler material is fed into the welding area vertically or at an angle.
11. A device for additive surfacing of metal products, comprising a unit for feeding filler material and a sequentially located unit for forming an initial laser beam, made from a laser radiation source and a laser beam expander, a unit for forming a rotating laser beam, describing the side surface of a cylinder during rotation, in the form of a system of rotating mirrors, a unit for forming a rotating laser beam, describing the side surface of a cone during rotation, wherein the guide channel of the unit for feeding filler material is located coaxially to the cone described by the laser beam.
12. The device according to paragraph 11, characterized in that it is additionally equipped with at least one rotating mirror located after the unit for forming a rotating laser beam, which describes the side surface of the cylinder during rotation.
13. The device according to paragraph 11, characterized in that the unit for forming a rotating laser beam, which describes the lateral surface of the cone during rotation, is made in the form of a sequentially located focusing lens and protective glass.
14. The device according to paragraph 11, characterized in that the unit for forming a rotating laser beam, which describes the lateral surface of a cone during rotation, is made in the form of a sequentially arranged rotating platform with a mirror, a rotating mirror system rotating synchronously with the mirrors, and protective glass.
15. The device according to paragraph 11, characterized in that the unit for forming a rotating laser beam, which describes the lateral surface of the cone during rotation, is additionally equipped with a diaphragm that rotates synchronously with the mirrors of the rotating mirror system.
16. The device according to paragraph 13, characterized in that the guide channel of the filler material feed unit, passing through the unit for forming a rotating laser beam, which describes the side surface of the cylinder during rotation, into the surfacing area, is introduced into the cavity of the laser beam, which describes the side surface of the cylinder during rotation, vertically from above through the opening of the rotating mirror, located between the unit for forming a conical laser beam and the system of rotating mirrors.
17. The device according to item 11, characterized in that the guide channel of the filler material feed unit is inserted into the cavity of the laser beam, which describes the side surface of the cylinder during rotation, from the side or from above.
18. The device according to paragraph 11, characterized in that the guide channel of the filler material feed unit is directed into the surfacing area vertically or at an angle of no more than 30°.