Dual-Chamber Cooled Jet Nozzle for Defect-Controlled Laser Deposition
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Solution Overview
Problem
Laser deposition welding methods often result in imperfections such as lack of fusion, pores, cracks, and dissolution of hard material particles in the functional layer, which degrade the load capacity and integrity of the welded joint.
Innovation Solution
A jet nozzle with a light channel and an outer structure featuring a radially inner and outer cooling chamber system, which guides a laser beam and a powdered filler material, ensuring efficient heat management and precise control of thermal processes through multiple independent zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser deposition welding is performed to increase load capacity, then the functional layer provides wear protection and increased strength, but imperfections such as lack of fusion, pores, cracks, and dissolution of hard material particles occur in the internal material structure
Solution Approach 1:
The nozzle is divided into multiple independent cooling zones (first cooling zone with first coolant flow path, second cooling zone with second coolant flow path) that can be controlled separately. This segmentation allows different thermal management strategies for different regions of the nozzle, enabling precise control of the laser beam and powder flow thermal interactions to prevent imperfections while maintaining the functional layer's load capacity enhancement
2Device complexity
If conventional cooling systems are used in the nozzle, then thermal management is simplified, but insufficient cooling leads to thermal degradation of the functional layer and nozzle structure
Solution Approach 1:
The cooling system is segmented into multiple independent cooling zones with separate coolant flow paths. The first cooling zone cools the region where the laser beam interacts with the functional layer, while the second cooling zone cools the region where powder flow interacts with the functional layer. This segmentation enables precise thermal control in each zone, preventing thermal degradation without requiring excessive overall cooling power
Solution Approach 2:
Different cooling strategies are applied to different regions of the nozzle based on their specific thermal requirements. The first cooling zone provides cooling tailored to the laser beam interaction region, while the second cooling zone provides cooling tailored to the powder flow interaction region. This local quality approach ensures optimal thermal management in each zone, preventing thermal degradation of the functional layer and nozzle structure
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 nozzle reduces or eliminates imperfections like lack of fusion, pores, and cracks, enhancing the quality and durability of the welded joint by maintaining consistent thermal control and preventing material degradation.
Implementation Method 1
a cooling system, which has a radially inner cooling chamber at least in sections and a radially outer cooling chamber at least in sections, through which a coolant flows
Implementation Method 2
a light channel for guiding at least one laser beam that is directed onto a workpiece
Data Source
AI summary
A jet nozzle for laser deposition welding along a feed direction includes a light channel for guiding at least one laser beam that is directed onto a workpiece, and an outer structure that surrounds the light channel at least in sections and extends from a flange portion to a distal region, which is formed by a nozzle mouth and from which the laser beam emerges. The outer structure includes a cooling system, which has a radially inner cooling chamber at least in sections and a radially outer cooling chamber at least in sections, through which a coolant flows.