Cooled Wire Deposition Nozzle for High-Power Laser Metal Additive
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Solution Overview
Problem
The existing laser metal wire deposition process is hindered by the frequent melting of the nozzle tip, leading to interruptions, reduced deposition rate, and increased costs due to frequent nozzle replacements, which contradicts the trend of increasing manufacturing efficiency by enhancing deposition rates.
Innovation Solution
The implementation of a cooling system for the nozzle, utilizing a metal block as a heat sink with a rear cooling portion and a coolant circuit to absorb and dissipate heat, thereby preventing significant melting and extending the nozzle's operational life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the laser power is increased to enhance deposition rate, then the productivity is improved, but the nozzle tip melts faster leading to more frequent interruptions
Solution Approach 1:
A cooling circuit is introduced as an intermediary system between the nozzle and the heat source. The cooling circuit circulates coolant through channels in the nozzle body, acting as a mediator to remove excess heat from the nozzle tip while allowing the high-power laser to continue operating. This enables the nozzle to withstand higher laser powers without melting, thus resolving the contradiction between increased productivity and maintained reliability.
2Productivity
If the deposition process is run continuously without interruption, then the productivity is improved, but the nozzle tip accumulates heat leading to melting
Solution Approach 1:
The cooling circuit enables continuous operation of the deposition process by providing ongoing heat removal. The coolant continuously circulates through the nozzle, maintaining thermal balance during extended operation. This allows the useful action (deposition) to continue without interruption while preventing the harmful accumulation of heat at the nozzle tip, thus resolving the contradiction between continuous operation and temperature control.
3Manufacturing precision
If the nozzle is replaced frequently to maintain deposition quality, then the manufacturing precision is improved, but the loss of time increases
Solution Approach 1:
The cooling circuit is installed in advance in the nozzle design, performing preliminary protection against heat accumulation. By pre-equipping the nozzle with active cooling capability, the system prevents the condition that would lead to nozzle failure and subsequent replacement. This preliminary protective action eliminates the need for frequent nozzle replacements, thus maintaining deposition quality while avoiding the time loss associated with replacement operations.
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 solution allows for continuous operation exceeding ten hours without nozzle replacement, enabling faster deposition rates and reducing costs by maintaining productivity and extending nozzle lifespan, while also allowing for increased laser power usage.
Implementation Method 1
a cooling system for the nozzle, utilizing a metal block as a heat sink with a rear cooling portion and a coolant circuit to absorb and dissipate heat
Implementation Method 2
utilizing a metal block as a heat sink with a rear cooling portion and a coolant circuit to absorb and dissipate heat
Data Source
Figure 1A
Figure 1B~1C
Figure 2
AI summary
A wire dispenser (9) for a laser metal wire deposition machine comprises a longitudinal duct (8) for guiding a wire (4A, 4B) from a proximal end (81) to a distal end (82) of the duct (8). A nozzle unit (6) is connected to the distal end (82) of the duct (8) and has a through bore (51) for receiving the wire (4B) from the distal end (82) of the duct (8) and for discharging the wire (4B) adjacent to a laser metal wire deposition site (16). The nozzle unit (6) includes a cooling circuit (771) for a cooling liquid.