Additive Manufacturing Base Material Heating With Scaled Irradiation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing additive manufacturing processes face challenges in managing thermal gradients and material fatigue due to discontinuous operation cycles, particularly in high-performance materials like nickel- or cobalt-based superalloys used in turbo machines, which affect thermo-mechanical properties and structural integrity.

Innovation Solution

A method involving scaled irradiation parameters, using a laser or electron beam for pre- and post-heating, with a scaling factor applied to the energy beam diameter and other parameters to optimize thermal management during the additive manufacturing process, including pre-heating and post-heating strategies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional additive manufacturing processes are used with standard irradiation parameters, then the manufacturing process can be completed, but thermal gradients and material defects occur leading to reduced structural integrity

Engineering Contradiction:

Improvestructural integrityVSAvoidthermal gradients

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary heating before the actual melting process to gradually increase the temperature of the base material and manufacturing plane. This pre-heating action reduces thermal shock and minimizes thermal gradients during subsequent laser melting, thereby improving structural integrity while reducing harmful thermal stress

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements a scaling factor approach that dynamically adjusts irradiation parameters (power, speed, hatch distance) based on the build layer number and position. By changing these parameters adaptively, the system optimizes heat input to reduce thermal gradients and prevent material defects, directly addressing the reliability issue

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If discontinuous operation cycles are applied to meet peaker plant demand, then operational flexibility is improved, but material fatigue increases due to repeated warming and cooling cycles

Engineering Contradiction:

Improveoperational flexibilityVSAvoidmaterial fatigue resistance

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent implements post-heating processes with scaled irradiation parameters after component fabrication to reduce residual stresses from discontinuous operation cycles. By adaptively adjusting heating parameters based on the specific operational history and thermal state, the system mitigates material fatigue while maintaining operational flexibility for peaker plant applications

Inventive Principle:

Principle #35Parameter changes

3Productivity

If standard laser melting parameters are used, then the additive manufacturing process can proceed efficiently, but thermal management is suboptimal leading to material defects

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidthermal management quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent transforms static irradiation parameters into dynamic, adaptive parameters that change during the manufacturing process. The scaling factor mechanism continuously adjusts laser power, scan speed, and hatch distance based on build layer number and position, enabling optimal thermal management that prevents defects while maintaining high manufacturing efficiency

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

By implementing scaled irradiation parameters that evolve throughout the additive manufacturing process, the system optimizes thermal input at each build stage. This dynamic parameter adjustment ensures efficient manufacturing while preventing thermal defects, resolving the contradiction between productivity and manufacturing precision

Inventive Principle:

Principle #35Parameter changes

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

Improves the structural and thermo-mechanical properties of components by reducing thermal gradients and material defects, enhancing the efficiency and automation of the additive manufacturing process for complex components.

Implementation Method 1

providing an energy beam, in particular a laser or electron beam, for the heating of the base material

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

providing an energy beam, in particular a laser or electron beam, for the heating of the base material

Methodology Applied

Scientific EffectElectron beam heating: Electron Beam

Implementation Method 3

irradiating the manufacturing plane with the energy beam under scaled irradiation parameters

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS12403656B2Method for heating a base material in additive manufacturing

Publication Date: 2025.09.02 SIEMENS ENERGY GLOBAL GMBH & CO KG

AI summary

A method for heating a base material in additive manufacturing includes a) providing an energy beam for the heating of the base material, wherein the base material is arranged to at least partly form a manufacturing plane, and b) irradiating the manufacturing plane for the heating with the energy beam under scaled irradiation parameters, wherein the scaled irradiation parameters are derived in that irradiation parameters for fusing the base material are scaled by a scaling factor, and wherein the scaling factor includes a quotient of a heating beam diameter and a fusion beam diameter.