3D Cladding Toolpaths for Complex Hybrid Article Repair
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Solution Overview
Problem
Current component repair processes, such as laser cladding, are limited by two-dimensional toolpath generation, leading to restricted build height and geometry, requiring significant post-processing and material loss, especially when forming complex shapes.
Innovation Solution
A method involving a three-dimensional additive manufacturing process where a cladding system directs sequential layers onto a build surface based on a user-selected model, aligning contours and generating toolpaths that conform to the part's geometry in three dimensions, allowing for the formation of complex geometries with reduced post-processing needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two-dimensional toolpath generation is used for laser cladding repair, then the process is simple to implement, but the build height and geometry are limited to the shape of the first layer
Solution Approach 1:
The patent transitions from two-dimensional toolpath generation to three-dimensional adaptive toolpath generation. The system captures the actual part geometry using vision systems and generates toolpaths that conform to the three-dimensional build surface, enabling complex geometries and variable build heights while maintaining ease of operation through automated 3D modeling and adaptive path calculation.
2Ease of operation
If two-dimensional toolpath is repeated for each layer, then the process is easy to control, but significant post-processing is required to achieve satisfactory repair
Solution Approach 1:
The patent implements dynamic toolpath generation that adapts to each layer's actual geometry. Instead of repeating static two-dimensional paths, the system continuously updates toolpaths based on vision system feedback and accumulated layer geometry, allowing the build process to dynamically conform to the desired complex shape while maintaining automated control.
3Adaptability or versatility
If discrete toolpaths are created for each layer to form complex shapes, then geometry flexibility improves, but material loss and post-processing increase
Solution Approach 1:
The patent performs preliminary three-dimensional modeling and toolpath planning before the actual cladding process. By pre-calculating the complete 3D geometry and generating adaptive toolpaths in advance, the system optimizes material deposition paths to minimize gaps, overlaps, and material waste, while ensuring the final complex geometry is achieved with reduced post-processing requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the creation of complex geometries with reduced post-processing requirements and material loss, enabling the repair and modification of parts with enhanced accuracy and repeatability, including the recovery of unsalvageable parts and the addition of new features, thus improving component performance.
Implementation Method 1
directing a cladding system to direct two or more cladding layers onto the build surface according to the additive structure model
Implementation Method 2
laser cladding repair
Data Source
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AI summary
Methods for preparing a hybrid article include disposing an additive structure (245) comprising a plurality of layers on a build surface (210) of a part, the build surface (210) being defined based on x, and y coordinates, and the additive structure (245) being defined by a three dimensional model defined by a series of planes based on x, y and z coordinates that define a plurality of layers, one layer comprising an interface surface (225) having a contour being defined by x, and y coordinates. When the build surface (210) and the interface surface (225) are both oriented in space according to corresponding x, y and z coordinates, a cladding system is directed to deposit each of the sequential layers of the additive structure (245) according to toolpaths that correspond with each of the plurality of layers of the three dimensional model.