Double-Mirror Laser Cladding Optics for Stable High-Intensity Focusing
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Solution Overview
Problem
Existing inside-beam powder-feeding laser-cladding technologies face issues with unstable energy of the light spot, poor adaptability, high sensitivity to optical axis misalignment, and low focusing intensity, leading to suboptimal laser processing results.
Innovation Solution
A double-mirror focusing inside-beam powder-feeding laser-cladding device is developed, which forms an annular laser beam using a first and second reflection beam splitter, and then focuses it with a focusing lens to create a high-intensity light spot, reducing aberration and sensitivity to optical axis misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a parabolic reflection focusing form is used, then the laser beam can be focused, but the sensitivity to optical axis misalignment is extremely high, making it easy to generate coma and astigmatism, which greatly reduces light intensity of the focused light spot
Solution Approach 1:
The patent divides the single parabolic mirror into two separate spherical mirrors (first and second spherical mirrors). Each mirror independently focuses a portion of the laser beam, avoiding the high sensitivity to misalignment inherent in a single parabolic mirror system. The segmented approach allows each mirror to operate within a more tolerant optical geometry.
Solution Approach 2:
Instead of using a conventional single parabolic mirror that requires precise optical axis alignment, the patent inverts the approach by using two spherical mirrors with their optical axes perpendicular to each other. This inverted configuration transforms the problem from one of precise axial alignment to a more robust perpendicular axis arrangement, significantly reducing sensitivity to misalignment.
2Device complexity
If conventional focusing methods are used, then the structure is simple, but the focusing intensity is poor, requiring a larger functional laser to complete laser cladding processing
Solution Approach 1:
The patent merges the focusing functions of two spherical mirrors into a single optical system. The first spherical mirror focuses the laser beam in one direction, and the second spherical mirror further focuses it in a perpendicular direction, achieving high-intensity focusing that would require a much larger laser if used alone. This combining approach concentrates energy more effectively than conventional single-mirror systems.
3Adaptability or versatility
If inside-beam powder-feeding laser-cladding is performed, then the laser beam can be delivered to the workpiece, but the light spot energy is unstable and adaptability is poor
Solution Approach 1:
The patent segments the powder feeding system into multiple nozzles arranged in specific patterns, with each nozzle delivering powder to a different region. This segmentation allows independent optimization of powder delivery to each focal region, improving both the stability of energy distribution and the adaptability to different cladding requirements.
Solution Approach 2:
The patent introduces a vertical dimension to the optical system by arranging the two spherical mirrors and multiple powder nozzles in three-dimensional space. The first mirror operates in one vertical plane while the second mirror operates in a perpendicular vertical plane, creating a multi-dimensional powder delivery and focusing system that enhances both stability and adaptability.
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 device achieves a high-intensity focused light spot with reduced aberration and sensitivity to optical axis misalignment, improving the adaptability and efficiency of laser cladding processes while maintaining low processing difficulty and cost.
Implementation Method 1
a laser beam is formed into a collimated beam through the collimated lens group
Implementation Method 2
the collimated beam is then reflected by the first reflection beam splitter and the second reflection beam splitter, and is offset outwards relative to a central axis to form an annular laser beam
Implementation Method 3
the annular laser beam is irradiated and focused by the focusing lens to form a light spot
Data Source
AI summary
A double-mirror focusing inside-beam powder-feeding laser-cladding device includes: first and second reflection beam splitters, a focusing lens, a vertical piping powder feeding device, and a collimated lens group. The first reflection beam splitter is disposed at a side of the collimated lens group; the second reflection beam splitter is disposed outside the first reflection beam splitter; the focusing lens is disposed at a side of the second reflection beam splitter facing away the collimated lens group; and the vertical piping powder feeding device is disposed at a side of the first reflection beam splitter facing away the collimated lens group. When the device is in use, a collimated beam is formed through the collimated lens group, and then reflected by the first and second reflection beam splitters to form an annular laser beam that can be focused by the focusing lens to form a light spot.