Auger-Based Filler Distribution for Laser Cladding
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Solution Overview
Problem
Current laser cladding techniques for superalloy components, such as turbine blades, face challenges in achieving uniform filler material distribution and fusion across multi-dimensional surfaces, leading to issues like lack of fusion, microcracking, and strain age cracking due to non-uniform heat input and filler material scattering, especially when applying multiple layers.
Innovation Solution
A laser cladding filler material distribution apparatus with a linear or polygonal array of dispensing apertures and a mechanical feed mechanism using an auger, which allows for selective variation in filler material feed rate and distribution pattern, ensuring uniform filler application across varying substrate surfaces during laser cladding, without relying on pressurized gas to prevent clumping and ensure even distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If pressurized gas is used to distribute filler material during laser cladding, then filler material can be delivered to the substrate surface, but non-uniform distribution and filler material scattering occur leading to microcracking and lack of fusion
Solution Approach 1:
The distribution apparatus divides the filler material delivery system into multiple discrete dispensing apertures arranged in an array, where each aperture delivers filler material to a specific location. This segmentation enables precise control over filler distribution patterns and eliminates the scattering problems associated with pressurized gas delivery.
Solution Approach 2:
The invention replaces the pneumatic (pressurized gas) delivery system with a mechanical auger-based delivery system. The auger mechanically transports filler material through sealed channels to the dispensing apertures, providing controlled, uniform delivery without the turbulence and scattering caused by pressurized gas flow.
2Volume of moving object
If multiple laser-welded cladding passes are applied to build surface volume, then larger cladding surface area and volume coverage are achieved, but microcracks and defects appear in the deposited material and underlying substrate
Solution Approach 1:
The distribution apparatus pre-positions filler material uniformly across the substrate surface before laser irradiation begins. This preliminary uniform distribution ensures that when multiple cladding passes are applied, each pass receives consistent filler material supply, preventing the microcracks and defects that arise from non-uniform filler distribution in subsequent passes.
Solution Approach 2:
The apparatus enables selective variation of filler material feed rate and distribution pattern parameters to match the specific requirements of different cladding passes and substrate geometries. By adjusting these parameters, the system maintains optimal filler distribution uniformity across multiple passes, preventing material integrity issues.
3Strength
If a fixed-optic laser is used for laser beam micro cladding, then focused laser optical energy liquefies filler material and heats substrate surface for good coalescence, but the process is limited to spot area and requires multiple passes for larger areas
Solution Approach 1:
The distribution apparatus uses an array of multiple dispensing apertures that can be arranged in linear or polygonal patterns, allowing filler material to be distributed across extended areas simultaneously. This segmented aperture array enables the system to maintain good coalescence quality at each spot while efficiently covering larger surface areas through coordinated multi-aperture operation.
Solution Approach 2:
The apparatus transitions from single-point filler delivery to multi-point distributed delivery by arranging apertures in two-dimensional arrays. This dimensional expansion allows the system to maintain the quality benefits of focused laser-cladding while significantly increasing the effective cladding area coverage per unit time through parallel filler distribution at multiple locations.
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 apparatus enables uniform filler material distribution and improved fusion across multi-dimensional surfaces, reducing microcracking and strain age cracking by maintaining consistent energy transfer and filler thickness, even in complex geometries, thus enhancing the structural integrity of repaired or built-up superalloy components.
Implementation Method 1
a laser beam transferring optical energy to the substrate
Implementation Method 2
transfers optical energy to the substrate and filler material
Implementation Method 3
A mechanical feed mechanism comprising an auger is adapted for feeding filler material from the internal chamber through the distribution apertures
Data Source
Figure 1~3
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AI summary
Laser cladding filler material is introduced in a pattern on a on a substrate (200) by a filler distribution apparatus (300) having a linear or polygonal array of dispensing apertures (331-336) for uniform distribution in advance of or during a laser beam (180) transferring optical energy to the substrate (200). The distribution apparatus (300) includes a housing (310) (or assembly of coupled housings) that defines the distribution aperture array (331-336) and an internal chamber (320) in communication with the apertures (331-336) that is adapted for retention of filler material (F). A mechanical feed mechanism, such as an auger (340), is adapted for feeding filler material (F) from the internal chamber (320) through the distribution apertures (331-336). A feed mechanism drive system (135) is coupled to the mechanical feed mechanism (340), adapted for selectively varying filler material feed rate. The distribution aperture array (331-336) may be selectively reconfigured to vary selectively the filler material distribution pattern.