3D Toolpath Generation for Laser Cladding Repair
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Solution Overview
Problem
Current component repair processes using two-dimensional toolpaths for laser cladding are limited in forming complex geometries, requiring significant post-processing, material loss, and resource-intensive manual processes, especially for turbine engine components.
Innovation Solution
A process for preparing a three-dimensional toolpath for additive manufacturing, allowing for the alignment and adaptation of an additive structure model to match the geometry of a build surface, enabling the generation of complex geometries with reduced post-processing needs by using a CAD program interfaced with a cladding system to control laser cladding parameters and direct the formation of additive structures in 5-axis, 3+2 axis, or 3-axis programs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two-dimensional toolpath is used for laser cladding repair, then the process is simple to implement, but the geometry complexity is limited and post-processing requirements increase
Solution Approach 1:
The patent transitions from two-dimensional toolpath generation to three-dimensional toolpath generation. The system imports 3D coordinates of the build surface contour, aligns them with the additive structure model in 3D space, and generates discrete toolpaths for each layer that account for complex geometries in all three dimensions, enabling formation of complex shapes while maintaining automated process control
2Ease of manufacture
If two-dimensional toolpath is used for laser cladding repair, then the process is straightforward, but significant post-processing is required
Solution Approach 1:
The system performs preliminary alignment and adaptation of the additive structure model to the build surface contour before toolpath generation. By pre-aligning the 3D model coordinates with the actual build surface geometry and pre-generating layer-specific toolpaths, the system eliminates the need for post-forming operations such as welding and machining that would otherwise be required to achieve satisfactory component repair
3Device complexity
If two-dimensional toolpath is used for laser cladding repair, then the equipment requirements are minimal, but material loss increases
Solution Approach 1:
The patent replaces manual mechanical operations (post-forming welding and machining) with automated 3D toolpath-controlled laser cladding processes. The system uses computer-generated 3D coordinates and automated alignment algorithms to precisely deposit material layer by layer, eliminating material loss associated with manual post-processing operations while maintaining relatively simple equipment requirements
4Shape
If three-dimensional toolpath is used for additive structure formation, then complex geometries can be formed with reduced post-processing, but the toolpath generation process becomes more complex
Solution Approach 1:
The patent introduces an intermediary alignment process that bridges the build surface contour data and the additive structure model. The system imports 3D coordinates of the build surface, aligns them with the model's interface surface coordinates through coordinate transformation and geometric fitting, and uses this aligned reference framework to generate accurate 3D toolpaths for each layer, managing the complexity through structured intermediate processing steps
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 resource commitment and material loss, allowing for accurate and repeatable deposition of additive structures directly on components, facilitating the repair and enhancement of turbine engine components with minimal post-processing, and enabling the creation of hybrid features not feasible with two-dimensional toolpaths.
Implementation Method 1
laser cladding parameters for additive manufacturing... laser cladding repair... controlling laser cladding parameters... forming of the additive structure... cladding system to define toolpaths for two or more cladding layers
Data Source
AI summary
A process for providing a manufacturing modality for a hybrid article includes defining a model for a build surface on a part in a three dimensional space, and defining a model for an additive structure, the model including an interface surface of the additive structure that corresponds with the build surface in the three dimensional space. The process further includes orienting the x, y and z coordinates of each of the build surface of the part and the interface surface of the model in relation to a three dimensional work space, aligning contours of each of the build surface and the interface surface relative to the work space, and directing a cladding system to define toolpaths for two or more cladding layers that are defined by vertical planar segments or slices of the additive structure model.