Additive Manufacturing Beam Shaping for Stable Heat Conduction Welding
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Solution Overview
Problem
Existing additive manufacturing processes using energy beams with rotationally symmetrical intensity distributions, such as Gaussian profiles, face inefficiencies in energy consumption, material loss, and process stability issues due to vaporization and material entrainment, particularly in deep welding processes like keyhole mode welding.
Innovation Solution
Implementing a non-rotationally symmetrical intensity distribution for the energy beam with a local minimum in the center and increased intensity along the edge, optimized for heat conduction welding, using a combination of energy beams with controlled relative movement to achieve a quasi-stationary intensity profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rotationally symmetrical intensity distribution (Gaussian profile) is used for the energy beam, then the beam can be easily generated and focused, but it causes excessive energy consumption, material vaporization, and process instability in deep welding processes
Solution Approach 1:
The patent applies asymmetry by transforming the rotationally symmetrical Gaussian intensity distribution into a non-rotationally symmetrical intensity distribution. The new distribution features a local minimum in the central region and increased intensity along the edge, creating an asymmetric profile that prevents keyhole formation and material vaporization while reducing energy consumption. This asymmetric distribution is achieved through controlled superposition of multiple energy beams with different phases and amplitudes.
Solution Approach 2:
The patent changes the intensity distribution parameters from a standard Gaussian profile to a customized non-rotationally symmetrical profile. By adjusting the relative phases, amplitudes, and positions of multiple superimposed energy beams, the intensity distribution parameters are optimized to create a flat-top or plateau-like profile with enhanced edge intensity, thereby controlling the melting process without causing vaporization.
2Ease of manufacture
If a rotationally symmetrical intensity distribution is used, then the beam generation is simple, but it leads to material entrainment and loss during deep welding
Solution Approach 1:
The asymmetric intensity distribution with central minimum and enhanced edge intensity prevents the formation of deep keyholes that cause material splatter and entrainment. The modified profile distributes energy more uniformly across the melt pool, eliminating the concentrated central peak that drives material vaporization and loss.
3Loss of energy
If a non-rotationally symmetrical intensity distribution with local minimum in center and increased edge intensity is implemented, then energy consumption is reduced and material loss is minimized, but the beam generation and control becomes more complex
Solution Approach 1:
The patent merges multiple energy beams into a single composite beam with the desired non-rotationally symmetrical intensity distribution. By superimposing multiple beams with controlled phases and amplitudes, the complex intensity profile is achieved through combination rather than requiring a completely new beam generation mechanism. This approach balances the increased control requirements with the benefits of using existing beam sources.
4Reliability
If a non-rotationally symmetrical intensity distribution is used, then process stability is enhanced by preventing vaporization, but the irradiation strategy and control becomes more difficult
Solution Approach 1:
The patent optimizes the intensity distribution parameters to achieve a stable melt pool without keyhole formation. By carefully controlling the relative phases, amplitudes, and positions of superimposed beams, the intensity profile parameters are tuned to maintain process stability and prevent vaporization, thereby improving reliability while managing control complexity.
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 reduces energy consumption, minimizes material loss, and enhances process stability by maintaining the desired temperature profile for efficient heat conduction welding, thereby improving the quality and cost-effectiveness of additive manufacturing.
Implementation Method 1
the usually shapeless or flowable, generally powdery, build-up material is irradiated with at least one energy beam on a build field, and an area of incidence of the energy beam on the build field is moved in order to melt the build-up material
Implementation Method 2
an area of incidence of the energy beam on the build field is moved in order to melt the build-up material, at least locally in the region of the area of incidence or in a target region in and around the area of incidence
Implementation Method 3
for the solidification process, the usually shapeless or flowable, generally powdery, build-up material is irradiated with at least one energy beam on a build field
Implementation Method 4
optimized for heat conduction welding, using a combination of energy beams with controlled relative movement to achieve a quasi-stationary intensity profile
Data Source
AI summary
Disclosed is a method and device for generating additive manufacturing control data. The control data are generated such that the energy beam has an intensity distribution, at the area of incidence on the build field, in a see tion plane running perpendicularly to the beam axis of the energy beam, which intensity distributionhas at least one local minimum in a middle region along at least one secant of the intensity distribution in the section plane andhas an intensity profile curve, running along the edge of the intensity distribution, which intensity profile curve has, at least at one point, a maximum value, and, at least at one point in a region opposite the maximum value on the intensity profile curve, a minimum value.