Additive Manufacturing Beam Profile for Stable Heat Conduction Welding
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Solution Overview
Problem
Current additive manufacturing processes using deep penetration welding are inefficient due to high energy consumption, material loss, and instability, leading to increased costs and material waste, particularly with Gaussian intensity profiles that cause thermocapillary convection and material defects.
Innovation Solution
Generating control data for additive manufacturing that optimizes the intensity profile of the energy beam to achieve a non-rotationally symmetric distribution, which avoids deep penetration welding by maintaining an ideal surface temperature and controlling thermocapillary convection, thereby maximizing energy input and reducing material loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If deep penetration welding process is used with Gaussian intensity profile, then high penetration depth is achieved, but energy consumption increases and material loss occurs
Solution Approach 1:
The patent applies asymmetry by changing the laser intensity profile from a rotationally symmetric Gaussian distribution to a non-rotationally symmetric distribution. This asymmetric intensity profile is specifically designed to concentrate energy in a manner that achieves deep penetration without creating the thermocapillary convection that causes material loss and high energy consumption in conventional Gaussian profiles.
2Length of stationary object
If deep penetration welding process is used, then high penetration depth is achieved, but material loss and instability increase
Solution Approach 1:
The non-rotationally symmetric intensity profile prevents the formation of a stable keyhole that causes material ejection and loss. By distributing energy asymmetrically, the process avoids the thermocapillary convection currents that drive material loss in deep penetration welding, thereby reducing material waste while maintaining penetration depth.
3Shape
If Gaussian intensity profile is used, then rotationally symmetric energy distribution is achieved, but thermocapillary convection causes manufacturing defects
Solution Approach 1:
The patent deliberately introduces asymmetry in the intensity profile to eliminate thermocapillary convection. The non-rotationally symmetric distribution prevents the formation of convection currents that cause manufacturing defects, thereby improving product quality while still achieving the desired penetration and melting characteristics.
4Ease of manufacture
If conventional laser intensity profile is used, then simple beam generation is maintained, but energy efficiency is reduced
Solution Approach 1:
The patent changes the intensity distribution parameters of the laser beam from a conventional Gaussian profile to a non-rotationally symmetric profile. This parameter change optimizes energy efficiency by preventing thermocapillary convection and material loss, while the modified profile can still be generated using standard laser systems with appropriate optical elements.
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
This approach enhances energy efficiency, reduces material waste, and improves the quality of the manufacturing process by maintaining an even temperature distribution, allowing for thicker layers and more accurate detail resolution while minimizing defects.
Implementation Method 1
irradiating of the build-up material with at least one energy beam is carried out and in the process of this an impingement surface of the energy beam on the build field is moved in order to melt the build-up material
Implementation Method 2
melt the build-up material in a target area in and around the impingement surface
Implementation Method 3
avoiding thermocapillary convection and material defects
Data Source
AI summary
A method and device for generating control data for an additive manufacturing device are described, wherein build-up material is built up and selectively solidified. Irradiating the build-up material on a build field with at least one energy beam occurs An impingement surface of the energy beam is moved on the build field in order to melt the build-up material in a target area in and around the impingement surface. For generating the control data, optimization criteria and/or secondary and/or boundary conditions relating to a local target temperature distribution in the target area of the build-up material are defined so that melting of the build-up material is effected as heat conduction welding. Based on this, an optimized intensity profile of the energy beam is determined, which is substantially non-rotationally symmetric at the impingement surface on the build field.