Cold Spray Nozzle Reorientation for 3D Printing Geometrical Accuracy
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Solution Overview
Problem
The low pressure cold spray (LPCS) technology faces challenges in controlling the additive process for producing bulk solid structured elements, such as thin walls and columns, due to difficulties in precisely adjusting the direction of spraying and powder buildup, which limits its feasibility for 3D component fabrication.
Innovation Solution
The implementation of 4 lasers conjugated with the LPCS nozzle and 4 digital cameras to control the shape of spray passes, allowing for real-time image analysis and adjustment of spraying parameters, including direction, thickness, and powder feed rate, to achieve precise control over the deposition process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If LPCS is used for additive manufacturing of bulk solid structured elements, then dense deposits with low oxygen content and free of residual tensile stresses are achieved, but the ability to precisely control the direction of spraying and powder buildup is insufficient
Solution Approach 1:
The system employs digital cameras to capture images of the deposited material in real-time, processes these images to determine the actual geometry of deposited passes, and uses this feedback information to automatically adjust spraying parameters including direction, powder feed rate, and deposition speed, enabling precise control of spray direction and powder buildup
Solution Approach 2:
The patent replaces manual operator control with an automated optical measurement and control system that uses digital images to monitor and adjust the spraying process, substituting mechanical/manual direction control with optical-field-based automated positioning and parameter adjustment
2Adaptability or versatility
If manual control of LPCS spraying is used, then operational flexibility is maintained, but the ability to adjust spray direction over short time intervals is insufficient for reproducing desired 3D shapes
Solution Approach 1:
The real-time image capture and processing system provides immediate feedback on the deposited geometry, enabling the control system to automatically adjust spray direction and parameters without manual intervention delays, achieving rapid adaptation to reproduce desired 3D shapes
Solution Approach 2:
The system performs self-adjustment of spraying parameters based on automatic image analysis and processing, with the control system independently modifying spray direction, powder feed rate, and deposition speed without requiring external operator input, enabling rapid response time
3Manufacturing precision
If LPCS spraying is performed without automated control, then system simplicity is maintained, but the precision of powder buildup process control is insufficient
Solution Approach 1:
The system uses digital cameras to capture images of the deposited material, processes these images to determine actual geometry, and feeds this information back to automatically adjust spraying parameters, achieving precise powder buildup control through closed-loop feedback
Solution Approach 2:
The patent introduces digital image processing as an intermediary between the spraying process and parameter adjustment, using optical field information from captured images to mediate and control the powder deposition process with high precision
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 enables the accurate reproduction of desired 3D shapes and geometries in bulk structural elements, improving the geometrical accuracy and microstructure density of fabricated components while maintaining the portability and cost-effectiveness of LPCS systems.
Implementation Method 1
The 4 lasers create on the substrate 4 light strips located around the LPCS-jet footprint
Implementation Method 2
The real-time information from 4 digital cameras perform image analysis of the light strips shapes in real time during spraying
Implementation Method 3
deposition of powder material onto a substrate using a nozzle controllably inclined relative to a vertical axis of a deposition surface to achieve the buildup formation of various elements of bulk structural elements
Data Source
AI summary
A method of forming a three dimensional object using a low pressure cold spray process for is disclosed. Powdered material is delivered at a temperature below the melting point of the powdered material. A nozzle of a cold spray gun is aligned at an angle θ1 to the substrate. The powdered material is delivered at a supersonic speed to the substrate causing the powdered material to adhere to the substrate for forming a first layer of material. An amount of optical distortion caused by the first layer of material adhered to the substrate is determined relative to the substrate and the nozzle is reoriented to an angle θ2 being offset from an axis defined by the first layer of material. A second layer of material is deposited onto the first layer of material with the nozzle being oriented at the angle θ2 to the first layer of material.