Cooled Wire Deposition Nozzle for Tip Melting Prevention

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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 replacements, which contradicts the trend of increasing manufacturing efficiency by enhancing laser power.

Innovation Solution

A wire dispenser with a nozzle unit incorporating a cooling circuit, featuring a metal front block acting as a heat sink and a rear cooling portion with a coolant circuit, effectively delays or prevents nozzle melting, allowing for continuous operation and increased productivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If laser power is increased to improve deposition rate, then productivity increases, but nozzle tip melting occurs more frequently

Engineering Contradiction:

Improvedeposition rateVSAvoidnozzle tip stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent changes the thermal parameters of the nozzle system by introducing active cooling and heat sink mechanisms. The cooling circuit modifies the temperature parameter of the nozzle tip, allowing it to withstand higher laser power settings without melting. This enables the system to operate at higher productivity levels while maintaining nozzle reliability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces a cooling fluid as an intermediary substance that transfers heat away from the nozzle tip. The heat sink acts as a thermal mediator between the laser energy and the nozzle tip, absorbing excess heat and preventing the nozzle from reaching melting temperatures even when exposed to high-power laser beams.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If nozzle replacement frequency is reduced to improve manufacturing efficiency, then productivity increases, but nozzle tip melting must be prevented

Engineering Contradiction:

Improvecontinuous operation timeVSAvoidnozzle tip melting

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary cooling action to the nozzle tip before it is exposed to high laser power. The cooling circuit is activated in advance to establish a thermal buffer, and the heat sink is positioned to intercept heat before it reaches critical levels. This preliminary thermal management prevents nozzle tip melting before it can occur, enabling continuous operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The heat sink provides beforehand cushioning by absorbing thermal energy before it can damage the nozzle tip. The cooling fluid circulates in advance to maintain the nozzle at a safe temperature, creating a thermal cushion that protects against the harmful effects of high laser power and allows prolonged continuous operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If cooling system is added to prevent nozzle melting, then nozzle reliability improves, but device complexity increases

Engineering Contradiction:

Improvenozzle tip stabilityVSAvoidnozzle unit structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the cooling circuit and heat sink into an integrated nozzle unit assembly. Rather than adding separate independent systems, the cooling channels are incorporated directly into the nozzle structure, and the heat sink is combined with the nozzle body. This integration reduces the number of separate components and simplifies the overall device while maintaining improved reliability.

Inventive Principle:

Principle #5Merging (Combining)

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 enables prolonged operation without nozzle replacement, potentially increasing deposition rates by allowing higher laser power settings, thus enhancing manufacturing efficiency and reducing costs associated with frequent nozzle replacements.

Implementation Method 1

a cooling circuit for a cooling liquid... effectively delays or prevents nozzle melting

Methodology Applied

Scientific EffectHeat absorption: Absorption (physical)

Implementation Method 2

a metal front block acting as a heat sink and a rear cooling portion with a coolant circuit

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

a metal front block acting as a heat sink

Methodology Applied

Scientific EffectHeat sink: Heat Sink

Data Source

PatentUS11498142B2Laser metal wire deposition

Publication Date: 2022.11.15 GKN AEROSPACE SWEDEN AB

AI summary

A wire dispenser for a laser metal wire deposition machine comprises a longitudinal duct for guiding a wire from a proximal end to a distal end of the duct. A nozzle unit is connected to the distal end of the duct and has a through bore for receiving the wire from the distal end of the duct and for discharging the wire adjacent to a laser metal wire deposition site. The nozzle unit includes a cooling circuit for a cooling liquid.