Annular Laser Wire Deposition Startup Power Control
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Solution Overview
Problem
The stability of the laser direct wire deposition (L-DWD) process is sensitive to initial transition phase parameters, particularly due to asymmetry and direction dependency, which affects the efficiency and symmetry of the process in additive manufacturing.
Innovation Solution
A processing machine with a control device that determines the initial laser beam power based on the workpiece irradiation proportion parameter (WIP) to ensure proper energy input for forming a molten bond between the workpiece and wire, using an annular laser beam and wire feeding mechanism to enhance stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wire is fed laterally into the molten pool generated by orthogonally directed laser beam, then the process is simpler to implement, but the efficiency and stability are influenced by angle of lateral feed and exhibit asymmetry
Solution Approach 1:
The patent applies asymmetry by inverting the conventional lateral feed arrangement to an axial feed configuration where the wire is fed along the axis of the annular laser beam. This fundamental geometric change from lateral to axial symmetry eliminates the asymmetry and direction dependency inherent in conventional setups, thereby improving process stability while maintaining implementation feasibility.
Solution Approach 2:
The patent transitions from two-dimensional lateral wire feed into the molten pool to three-dimensional axial wire feed through the center of the annular laser beam. This dimensional change allows the wire to be positioned symmetrically within the energy distribution zone, eliminating angular dependency and enhancing process reliability without significantly complicating the manufacturing setup.
2Reliability
If wire is fed axially relative to the laser beam to achieve symmetry and direction independence, then process stability improves, but the process becomes highly sensitive to parameters in the initial transition phase
Solution Approach 1:
The patent applies preliminary action by pre-positioning the wire end at a specific distance from the workpiece surface before laser irradiation begins. This predetermined initial configuration ensures that when the annular laser beam and wire are simultaneously activated, the wire end is already in the optimal position to receive laser energy, thereby reducing sensitivity to parameter variations during the critical initial transition phase while maintaining axial feed symmetry.
Solution Approach 2:
The patent utilizes parameter changes by optimizing the initial distance between wire end and workpiece surface, as well as the laser beam power distribution across the annular profile. By carefully controlling these parameters before and during the initial phase, the system achieves stable molten bond formation without excessive sensitivity to parameter fluctuations, thus maintaining high reliability while managing device complexity.
3Reliability
If laser beam power is increased to ensure adequate energy input for molten bond formation, then bonding reliability improves, but the risk of excessive heating and molten pool instability increases
Solution Approach 1:
The patent applies local quality through the annular laser beam configuration that concentrates energy in a specific ring-shaped zone around the wire end. This localized energy distribution ensures adequate heating for reliable molten bond formation at the wire-workpiece interface while avoiding excessive heating of the bulk material. The annular profile matches the geometry of the wire end, creating optimal local energy coupling without generating unstable large-scale molten pools.
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
The solution stabilizes the initial phase of additive manufacturing by ensuring simultaneous heating of the workpiece and wire, allowing for a smooth transition to a steady phase with improved process stability and reduced risk of molten bond formation issues.
Implementation Method 1
a laser irradiation device configured to irradiate a workpiece with an annular laser beam
Implementation Method 2
the workpiece and the wire are simultaneously heated by the laser beam by abutting the wire end on the workpiece surface
Implementation Method 3
a molten bond in an appropriate form can be formed between the workpiece surface and the wire end
Implementation Method 4
the workpiece and the wire are simultaneously heated by the laser beam by abutting the wire end on the workpiece surface
Data Source
AI summary
A processing machine includes a laser irradiation device that emits an annular laser beam, and a wire feeding device that feeds a wire from an inside of the annular laser beam. When a workpiece irradiation proportion parameter (WIP) represented by an equation WIP=Pwp/P (Pwp: laser beam power introduced onto a workpiece surface when the wire exists in an irradiation region of the laser beam, P: the laser beam power introduced onto the workpiece surface when the wire does not exist in the irradiation region) is defined, a control device controls the wire feeding device so that a wire end abuts on the workpiece surface at a beginning of additive manufacturing. The control device determines initial power P0 based on the WIP at the beginning of the additive manufacturing, and controls the laser irradiation device so that the workpiece is irradiated with the laser beam at the initial power P0.