DED Nozzle Powder Feed Layout for Even Powder Distribution
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Solution Overview
Problem
In Direct Energy Deposition (DED) methods, there is a challenge in evenly supplying powder material to the DED nozzle, which affects the consistency and quality of the fabricated three-dimensional objects.
Innovation Solution
The proposed solution involves an AM apparatus with a DED nozzle that includes a powder port and a powder passage. The apparatus also features a first pipe with a separation wall that divides it into multiple regions, each connected to a second pipe, which are in turn connected to the powder passage of the DED nozzle. This configuration ensures even distribution of the powder material to the DED nozzle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple powder passages and powder ports are formed in the DED nozzle to evenly supply powder, then the powder distribution uniformity is improved, but the device complexity increases
Solution Approach 1:
The first pipe is divided into multiple regions by the separation wall, with each region connected to a separate second pipe. This segmentation allows independent control and even distribution of powder material to multiple DED nozzle ports without requiring complex internal passages within the nozzle itself.
Solution Approach 2:
The separation wall acts as an intermediary structure that divides the first pipe into multiple regions. This intermediary element enables even powder distribution to multiple second pipes while keeping the DED nozzle structure relatively simple, resolving the contradiction between distribution uniformity and device complexity.
2Manufacturing precision
If powder is supplied through multiple passages to improve distribution, then the manufacturing precision is improved, but the loss of substance increases due to potential oxidation
Solution Approach 1:
By segmenting the powder supply system into multiple separate second pipes connected to a divided first pipe, each passage can be optimized for minimal exposure to oxygen. The separation wall creates distinct regions that can be individually sealed or controlled, reducing overall powder oxidation while maintaining even distribution.
3Device complexity
If a single powder passage is used to simplify the device structure, then the device complexity is reduced, but the manufacturing precision deteriorates due to uneven powder supply
Solution Approach 1:
The first pipe is segmented into multiple regions by the separation wall, with each region connected to a separate second pipe. This segmentation enables even powder distribution to multiple DED nozzle ports while maintaining a relatively simple overall structure, avoiding the need for complex internal passages within the nozzle.
Solution Approach 2:
Instead of creating complex three-dimensional internal passages within the DED nozzle, the invention resolves the distribution problem in a different dimension by using a separated pipe system with a separation wall that divides the first pipe into multiple regions, each connected to second pipes.
Data Source
AI summary
The present invention provides a technique for evenly supplying powder used as a material to a DED nozzle.According to one aspect, an AM apparatus for manufacturing a fabrication object is provided. This AM apparatus includes a DED nozzle. The DED nozzle includes a powder port provided at a distal end of a main body of the DED nozzle and configured to eject a powder material therefrom, and a powder passage provided in communication with the powder port and configured to allow the powder material to pass through inside the main body of the DED nozzle. The AM apparatus further includes a first pipe, a separation wall extending from an end portion of the first pipe toward an upstream side inside the first pipe, and a plurality of second pipes connected to the end portion of the first pipe. The separation wall divides the end portion of the first pipe into a plurality of regions, and the plurality of second pipes is connected to the plurality of regions of the first pipe, respectively. The second pipes are connected to the powder passage of the DED nozzle.