DED Nozzle Port Geometry for Powder Bed Fabrication
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Solution Overview
Problem
In Direct Energy Deposition (DED) additive manufacturing, the supply of carrier gas from the DED nozzle unintentionally blows off pre-beded metal powder, making it difficult to fabricate three-dimensional objects.
Innovation Solution
A DED nozzle design that includes a laser port and a powder port, with the directions of the powder passage and port determined based on the distance to the fabrication point, the velocity of the powder material, and gravitational acceleration, ensuring the powder is appropriately supplied to the fabrication point without being blown off.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If carrier gas is supplied from the DED nozzle to deliver powder material, then powder material can be supplied to the fabrication point, but the pre-beded metal powder is blown off due to the carrier gas flow
Solution Approach 1:
The nozzle is divided into separate functional ports: a powder port for delivering powder material and a gas port for supplying carrier gas. This segmentation allows independent control of powder and gas flows, enabling the carrier gas to be directed away from the powder bed while still delivering powder to the fabrication point, thus preventing powder bed disturbance
Solution Approach 2:
The nozzle structure acts as an intermediary device that separates the powder delivery path from the gas flow path. By providing distinct passages and ports for powder and gas, the nozzle mediates between the need for powder supply and the need to protect the powder bed, allowing both functions to coexist without interference
2Manufacturing precision
If the powder port is positioned to deliver powder to the fabrication point, then fabrication can proceed, but the laser port positioning becomes constrained
Solution Approach 1:
The nozzle is designed with multiple ports (powder port, gas port, laser port) that can function independently or in combination. This multi-functionality allows the same nozzle structure to handle both powder delivery and laser processing simultaneously, accommodating different fabrication scenarios without requiring multiple specialized nozzles, thereby managing complexity while maintaining precision
3Productivity
If the carrier gas velocity is increased to improve powder material delivery, then powder supply efficiency improves, but the powder bed is more severely disturbed
Solution Approach 1:
By segmenting the gas and powder delivery paths into separate ports and passages, the system can optimize gas velocity for powder delivery without compromising the powder bed. The carrier gas flows through a dedicated passage that directs it toward the fabrication point rather than over the powder bed, allowing higher gas velocities to be used for improved productivity without increased disturbance
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 design allows for successful fabrication by ensuring the powder material intersects with the laser at the intended point, even at low carrier gas velocities, preventing the powder bed from being disturbed.
Implementation Method 1
a laser port provided at a distal end of the DED nozzle main body and configured to emit laser light
Implementation Method 2
fabrication by melting and solidifying a metal material together with a base material using an appropriate heat source
Implementation Method 3
Directions of the powder passage and the powder port are determined based on a distance from the powder port to a fabrication point, a velocity of the powder material ejected from the powder port, and a gravitational acceleration
Data Source
AI summary
The present disclosure provides a technique for carrying out fabrication on a powder material bedded in advance using a DED nozzle. According to one aspect, a DED nozzle for use with an AM apparatus is provided. This DED nozzle includes a DED nozzle main body, a laser port provided at a distal end of the DED nozzle main body and configured to emit laser light, a laser passage provided in communication with the laser port and configured to allow the laser light to pass through inside the DED nozzle main body, a powder port provided at the distal end of the DED nozzle main body and configured to eject a powder material, and a powder passage provided in communication with the powder port and configured to allow the powder material to pass through inside the DED nozzle main body. Directions of the powder passage and the powder port are determined based on a distance from the powder port to a fabrication point, a velocity of the powder material ejected from the powder port, and a gravitational acceleration.