Dithered Collimated Laser Head for Uniform 3D Cladding
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Solution Overview
Problem
Existing laser processing systems face challenges in moving laser beams across complex three-dimensional surfaces while maintaining consistent power density, leading to inconsistent processing results due to variations in beam characteristics, particularly on turbine blades and other complex geometries.
Innovation Solution
A laser processing system that generates a collimated laser beam with consistent Z-axis power density, capable of dithering along the X and Y axes, using a beam delivery system with movable collimating lenses and a motion control system to maintain power density consistency during processing on three-dimensional surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the laser beam is focused to increase power density, then the power density at the focal point is improved, but the power density varies significantly at different locations along the beam length
Solution Approach 1:
The patent changes the optical parameter of the laser beam from focused to collimated, transforming the beam's propagation characteristics. This parameter change ensures that the beam maintains a consistent diameter and power density distribution along its entire length, resolving the contradiction between achieving high power density and maintaining consistency across different Z-axis locations.
2Adaptability or versatility
If the entire laser head is moved to change beam direction, then the beam can be directed to different areas, but the response time is slow
Solution Approach 1:
The patent segments the laser processing system into independent functional components: a stationary laser head and a separate beam steering mechanism using galvanometer mirrors. This segmentation allows the beam direction to be changed rapidly by moving only the lightweight mirrors rather than the entire heavy laser head, thus improving response time while maintaining beam directionality.
Solution Approach 2:
The patent introduces galvanometer mirrors as intermediary elements between the laser head and the workpiece. These mirrors act as mediators that can rapidly redirect the laser beam to different positions and angles without requiring physical movement of the laser head itself, thereby achieving fast response times while maintaining full adaptability in beam positioning.
3Power
If a focused beam is used for processing, then the power density is concentrated, but movement of the laser beam results in significant change in power density at different processing locations
Solution Approach 1:
The patent changes the beam propagation parameter from focused to collimated, which fundamentally alters how the beam interacts with the workpiece during movement. A collimated beam maintains its diameter and power density distribution regardless of small positional variations, ensuring consistent processing results across different locations while still delivering sufficient power density for effective laser cladding.
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
Enables efficient and consistent laser processing on complex surfaces by maintaining consistent power density across the workpiece, facilitating precise deposition of coatings and improved processing times on three-dimensional surfaces such as turbine blades.
Implementation Method 1
uses the laser to heat the workpiece sufficiently to allow another material to adhere to a surface the workpiece
Implementation Method 2
heat the workpiece sufficiently to allow another material to adhere
Data Source
Figure 1A~1C
Figure 2A~2D
Figure 3A~3B
AI summary
Laser processing systems and methods are capable of moving a laser beam while maintaining consistent laser beam characteristics at processing locations. The laser processing systems generate a collimated laser beam having a consistent Z axis power density along at least a portion of a length of the laser beam and dither the collimated laser beam along one of the X and Y axes. The dithering of the collimated laser beam facilitates consistent laser processing on a three-dimensional surface, for example, to provide consistent deposition of a coating in a laser cladding process. A laser processing system may include a beam delivery system that provides both the collimation and the dithering of the collimated laser as well as an adjustment of the beam diameter of the collimated beam.