Dynamic Gas Flow Control in Laser Additive Manufacturing
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Solution Overview
Problem
Laser additive manufacturing faces challenges with low production efficiency, product quality degradation due to slag and oxides falling back into the processing area during the melt forming process, which contaminates the product with impurities.
Innovation Solution
An additive manufacturing system and method that dynamically controls the angle between the gas flow direction and the energy beam's moving direction using an atmosphere controlling module, comprising gas inlet-outlet devices and a dynamic gas flow controlling device, to prevent slag and oxides from falling back into the processing area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser additive manufacturing is performed with conventional gas flow control, then the melt forming process can be completed, but slag and oxides fall back into the processing area causing product contamination
Solution Approach 1:
The gas flow controlling device dynamically adjusts the gas flow direction in real-time during the additive manufacturing process, changing the gas flow angle relative to the energy beam moving direction based on the current processing position. This dynamic adjustment prevents slag and oxides from falling back into the processing area, thereby improving product quality while maintaining manufacturing efficiency.
Solution Approach 2:
The invention changes the parameters of gas flow (specifically the angle between gas flow direction and energy beam moving direction) during the manufacturing process. By controlling this angle to be within a specific range (45°-135° or 225°-315°) relative to the energy beam scanning direction, the system effectively directs slag and oxides away from the processing area, reducing contamination without affecting the melt forming process.
2Manufacturing precision
If the gas flow direction is fixed during additive manufacturing, then the system structure is simple, but slag and oxides cannot be effectively prevented from falling back into the processing area
Solution Approach 1:
The invention introduces a gas flow controlling device as an intermediary component between the gas source and the processing area. This device acts as a mediator that dynamically adjusts gas flow direction without directly interfering with the energy beam or powder deposition processes, thereby preventing contamination while adding minimal system complexity.
Solution Approach 2:
The invention uses pneumatic control mechanisms to adjust the gas flow direction dynamically during the additive manufacturing process. By employing gas flow controllers and adjustable gas inlet/outlet devices, the system can change the angle and direction of gas flow without complex mechanical moving parts, reducing overall system complexity while achieving the desired contamination prevention.
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 approach improves the quality and stability of additive manufacturing by effectively reducing slag and oxide contamination, enhancing the forming process by adjusting the gas flow direction to match the energy beam's path, thereby preventing impurities from accumulating in the product.
Implementation Method 1
The technology of laser additive manufacturing makes use the principle of laser melting
Implementation Method 2
irradiating the powder with an energy beam and directing the energy beam on the powder to form a solidified layer
Implementation Method 3
The dynamic gas flow controlling device dynamically controls an angle between a flow direction of the gas and a moving direction of the energy beam
Data Source
AI summary
An additive manufacturing system is provided. The system includes: a stage, a powder supplying device, an energy beam generating device and an atmosphere controlling module. The powder supplying device provides powder to the stage. The energy beam-generating device generates an energy beam and directs the energy beam to the stage. The atmosphere controlling module includes at least one pair of gas inlet-outlet devices coupled around the stage, and a dynamic gas flow controlling device connected with the gas inlet-outlet devices. The dynamic gas flow controlling device dynamically controls an angle between a flow direction of the gas and a moving direction of the energy beam. The angle is predetermined by a scanning strategy.