Additive Manufacturing Carrier Gas Flow Control
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Solution Overview
Problem
Conventional additive manufacturing apparatuses face issues in maintaining a constant carrier gas supply while adjusting the powder supply rate according to the moving speed of the nozzle, leading to inadequate prevention of oxidation and shape accuracy in deposits.
Innovation Solution
An additive manufacturing apparatus with a flow rate adjuster and separator system that directs a portion of the carrier gas flow into a branch path, ensuring a constant carrier gas supply to the nozzle while adjusting the powder flow rate, using a cyclone separator for efficient powder-carrier gas separation and a backflow preventing member to maintain flow integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a three-way valve is provided in the powder supply path near the supply nozzle to adjust the powder supply rate according to moving speed, then the shape accuracy of deposits is improved, but the carrier gas supply amount is reduced causing oxidation of deposits
Solution Approach 1:
The supply path is divided into a main path and a branch path. The three-way valve divides the carrier gas flow into two segments: one through the main path to the supply nozzle, and another through the branch path to the separator. This segmentation allows independent control of powder supply rate and carrier gas supply amount, resolving the contradiction between shape accuracy and oxidation prevention.
Solution Approach 2:
A separator is introduced as an intermediary device in the branch path. The separator removes powder particles from the carrier gas flow that returns to the supply source, preventing powder loss and ensuring that only clean carrier gas is recycled. This intermediary component enables precise control of powder supply rate without compromising the protective carrier gas atmosphere.
2Productivity
If the powder supply rate is adjusted by controlling the three-way valve openness, then the moving speed and powder supply rate ratio is maintained, but the carrier gas flow rate becomes insufficient for protecting deposits
Solution Approach 1:
The carrier gas supply is segmented into two independent paths: the main path supplies carrier gas to the supply nozzle for powder transport, while the branch path supplies additional carrier gas through the separator for deposit protection. This segmentation ensures that powder supply rate can be adjusted independently without compromising the protective gas atmosphere.
Solution Approach 2:
The carrier gas system is designed with multi-functionality: the main path handles powder transport function, while the branch path through the separator provides the protective atmosphere function. This multi-functional design allows the system to simultaneously maintain accurate powder supply rate control and reliable deposit protection.
3Device complexity
If the three-way valve is positioned far from the supply nozzle, then the valve structure is simplified, but the response lag in powder supply adjustment increases
Solution Approach 1:
The valve system is segmented into two functional zones: the three-way valve is positioned in the branch path away from the nozzle for simplified structure and maintenance, while a separate powder supply control mechanism is integrated near the nozzle for rapid response. This spatial segmentation resolves the contradiction between structural simplicity and response speed.
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 configuration maintains a constant carrier gas supply to prevent oxidation and ensures accurate shaping of deposits by adjusting the powder flow rate in sync with nozzle movement speed, while allowing for efficient reuse of recovered powder.
Implementation Method 1
the branch flow path having a separator provided therein for separating the powder and the carrier gas
Implementation Method 2
the powder is heated and melted by the energy of the laser beam and deposits there
Implementation Method 3
laser-beam concentration spot (laser-beam focusing area) where the laser beam radiated by the laser beam radiating head is concentrated
Data Source
AI summary
An additive manufacturing apparatus includes a nozzle body discharging a powder and a carrier gas from an opening, a powder supply supplying the powder and the carrier gas to the nozzle body, a flow rate adjuster provided in a supply path of the powder supply to cause a part of a flow of the carrier gas containing the powder to flow into a branch flow path branching from the supply path to adjust a flow rate of the carrier gas containing the powder to be supplied to the nozzle body, and the branch flow path connected to the flow rate adjuster. The branch flow path is connected to a flow path leading to the nozzle body and has a separator for separating the powder and the carrier gas. The carrier gas separated from the powder by the separator is supplied to the nozzle body through the branch flow path.