Combination Energy Beam Control for Stable Melt Intensity
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in efficiently controlling the intensity distribution of energy beams, particularly in laser welding and selective laser melting, which affect energy consumption and product quality due to the need for frequent changes in intensity distribution orientation and spatial intensity patterns.
Innovation Solution
A method and device that utilize two energy beams with different intensity distributions, where a second energy beam is moved relative to a first energy beam to create a combination energy beam with a dynamically changeable overall intensity distribution, allowing for precise control of the irradiation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single energy beam with rotationally symmetrical intensity distribution is used for irradiation, then the device structure is simple and operation is easy, but the intensity distribution cannot be flexibly adjusted to match different manufacturing requirements
Solution Approach 1:
The patent divides a single energy beam into multiple sub-beams (first energy beam and second energy beam) with different intensity distributions. Each sub-beam can be independently controlled and moved relative to the other, enabling flexible combination of intensity patterns without requiring a completely complex new beam generation system.
Solution Approach 2:
The patent combines multiple energy beams with different intensity distributions into a single irradiation system. The first and second energy beams are superimposed and moved together as a combination energy beam, merging their functionality while maintaining individual controllability to achieve versatile intensity distribution management.
2Manufacturing precision
If the intensity distribution orientation is frequently changed during irradiation, then the manufacturing precision can be improved, but the energy consumption increases
Solution Approach 1:
The patent implements dynamic control of the second energy beam's position relative to the first energy beam during irradiation. This allows the overall intensity distribution to adapt dynamically to the manufacturing requirements while maintaining energy efficiency through optimized beam combination and coordinated movement.
Solution Approach 2:
The patent changes the relative position parameter of the second energy beam with respect to the first energy beam to achieve different intensity distribution orientations. This parameter adjustment enables precise control of the combined intensity pattern without requiring complete system reconfiguration, thereby reducing energy consumption.
3Adaptability or versatility
If multiple energy beams are used with different intensity distributions, then the adaptability of intensity distribution is improved, but the device complexity increases
Solution Approach 1:
The patent creates a multi-functional beam movement system where the first and second energy beams can be independently positioned and combined. The same system infrastructure handles multiple functions: generating different intensity distributions, adjusting their relative orientations, and coordinating their movement, thereby achieving versatility without proportionally increasing complexity.
4Productivity
If the area of incidence is moved during irradiation, then the productivity is improved, but maintaining quasi-stationary intensity distribution becomes more difficult
Solution Approach 1:
The patent pre-establishes the intensity distribution pattern by combining the first and second energy beams before movement begins. The relative positions of the sub-beams are determined in advance, creating a stable overall intensity distribution that remains consistent during the irradiation process, even as the combined beam moves across the material.
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
Enables efficient and flexible intensity distribution management, reducing energy consumption and improving the quality of manufactured products by ensuring quasi-stationary intensity distribution during the additive manufacturing process.
Implementation Method 1
irradiation with radiant energy, for example electromagnetic radiation, in particular light and/or heat radiation
Implementation Method 2
the powder grains of the build-up material are partially or completely melted with the help of the energy locally introduced by the radiation at this location
Implementation Method 3
at least a first energy beam and a second energy beam are generated and at least partially superimposed as a combination energy beam which is moved together with the first energy beam and the second energy beam moving relative thereto
Data Source
AI summary
A method and an irradiation device for locally melting a material are described, wherein an area of incidence of the energy beam on the material is moved. In the process, at least one first energy beam and one second energy beam are generated, the second energy beam is moved relative to the first energy beam and the first energy beam and the second energy beam are coupled in a common beam path into an energy beam movement unit in such a way that they are moved together over the material as a combination energy beam.