Eccentric Laser Deposition Head for Rotary Components
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Solution Overview
Problem
In extreme high-speed-rate laser direct energy deposition manufacturing of large rotary engineering components, issues arise such as shortened service life of the machining head due to laser reflection, incomplete bonding of the molten pool with the substrate, and manufacturing defects like cracks and air holes, leading to increased production costs and surface roughness.
Innovation Solution
An eccentric extreme high-speed-rate laser hybrid manufacturing method is introduced, where the laser machining head is positioned at a predetermined eccentric distance to reduce damage from reflected light and enhance bonding, combining high-speed-rate laser direct energy deposition with laser remelting to improve deposition layer quality and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If extreme high-speed-rate laser direct energy deposition is used for long-time manufacturing on rotary engineering components, then deposition rate and surface performance are improved, but service life of the laser machining head is greatly shortened due to laser reflection
Solution Approach 1:
The patent applies asymmetry by positioning the laser machining head at an eccentric location relative to the rotary engineering component. The eccentric distance is specifically set to position the machining head outside the laser reflection path, thereby avoiding damage from reflected laser while maintaining effective deposition. This asymmetric positioning resolves the contradiction by protecting the machining head without sacrificing productivity.
2Productivity
If high-speed rotating substrate is used, then deposition efficiency is improved, but molten pool moves away from substrate top and cannot be fully bonded due to short solidification time under gravity influence
Solution Approach 1:
The patent introduces a new spatial dimension by using eccentric positioning. Instead of only adjusting parameters within the traditional coaxial deposition framework, the machining head is positioned offset from the rotation axis, creating a three-dimensional spatial arrangement that allows the laser beam to intersect the substrate at an optimized angle and location. This dimensional change enables the molten pool to remain properly positioned on the substrate surface despite high rotation speeds, ensuring complete bonding while maintaining high deposition efficiency.
3Area of stationary object
If large-area extreme high-speed-rate laser direct energy deposition is performed, then manufacturing coverage is improved, but manufacturing defects such as cracks, air holes, and surface roughness increase
Solution Approach 1:
The patent employs laser remelting as an intermediary process between direct energy deposition and final part completion. The remelting process acts as a mediator that repairs defects introduced during high-speed deposition. By applying controlled laser remelting passes over the deposited material, the process eliminates cracks, air holes, and excessive surface roughness, thereby enabling large-area manufacturing while maintaining high quality standards.
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 method prolongs the service life of the machining head, ensures complete bonding of the molten pool, and significantly improves the surface quality and compactness of the deposition layer, reducing defects and production costs.
Implementation Method 1
an additive material and a surface of a high-speed moving substrate material are molten simultaneously, with a high-energy-density beam
Implementation Method 2
The molten materials are solidified rapidly to form a deposition layer with an ultra-low dilution rate, and a metallurgical bond with the substrate
Implementation Method 3
due to long-time reflection of laser, the service life of a core member (mainly a laser machining head) is greatly shortened
Data Source
AI summary
The present disclosure relates to an eccentric extreme high-speed-rate laser hybrid manufacturing method for a rotary engineering component. By positioning an extreme high-speed-rate laser direct energy deposition machining head at a predetermined eccentric distance, the damage caused by reflected light to the machining head is effectively reduced, to prolong a service life of the machining head. Also a conventional form of a molten pool in extreme high-speed-rate laser direct energy deposition can be changed, namely from a “falling” form caused by a high-speed movement and a gravity to a “climbing” form. Thus, in extreme high-speed-rate laser direct energy deposition machining, the molten pool has a longer time to fully contact a surface of the rotary engineering component to form desirable bonding performance.