Embedded Cooling Probes for Additive Manufacturing Layer Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for controlling the cooling rate in multilayer structure manufacturing are inadequate, as they either fail to adjust the cooling rate at specific layer regions, provide insufficient cooling capacity, or interfere with the formation of metal structures during the additive manufacturing process.
Innovation Solution
A multilayer structure manufacturing device equipped with temperature measurement and adjustment probes embedded inside the powder bed, allowing for precise control of the cooling rate using the Joule-Thomson effect and liquefied gases, which are extendable and integrated with a shield gas supply system to manage the cooling process without interfering with layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cooling methods are used to control the cooling rate of the entire multilayer structure, then the cooling process can be managed, but the cooling rate cannot be adjusted at any specific point in the multilayer structure
Solution Approach 1:
The cooling control system is segmented into multiple independent cooling devices, each capable of controlling the cooling rate at specific points or regions of the multilayer structure. This allows localized cooling rate adjustment without requiring complex centralized control, resolving the contradiction between precision and complexity.
Solution Approach 2:
Different regions of the multilayer structure are assigned different cooling rates according to their specific requirements. The patent implements local quality control by enabling independent cooling rate adjustment at various points, allowing each region to have optimized cooling characteristics without affecting the entire structure uniformly.
2Temperature
If energy ray irradiation source is used to control the temperature gradient of layer regions, then heating control is improved, but the cooling capacity becomes insufficient when target temperature is low
Solution Approach 1:
The patent combines heating devices (energy ray irradiation sources) and cooling devices into a single integrated system. This merging allows the system to perform both heating and cooling functions, resolving the contradiction where heating control was improved but cooling capacity became insufficient.
Solution Approach 2:
The temperature control system is designed with multi-functionality, where the same system can perform both heating (via energy ray irradiation) and cooling (via dedicated cooling devices) operations. This universal design allows the system to adapt to different temperature control requirements without being limited to a single function.
3Manufacturing precision
If processing parameters are adjusted to control solidification rate, then some control is achieved, but the cooling rate cannot be increased beyond natural cooling limits
Solution Approach 1:
The patent replaces natural cooling mechanisms with active cooling devices that use controlled fluid circulation and heat exchange. This substitution allows the cooling rate to exceed natural cooling limits while maintaining precise control, resolving the contradiction between control precision and cooling rate capability.
Solution Approach 2:
The system enables dynamic changes in cooling parameters (such as coolant flow rate, temperature, and circulation speed) to achieve higher cooling rates. By actively modifying these parameters, the system can increase the cooling rate beyond natural limits while maintaining precise control over the solidification process.
4Temperature
If striking tool is used to cool the weld bead, then cooling control is achieved, but the impact interferes with metal powder layer and formation process
Solution Approach 1:
The patent introduces a fluid-based cooling medium as an intermediary between the cooling source and the weld bead. This intermediary approach allows heat removal without direct mechanical contact, eliminating the harmful impact on the metal powder layer while maintaining effective cooling control.
Solution Approach 2:
The cooling system uses pneumatic or hydraulic mechanisms to deliver cooling fluid to the weld bead area. This approach replaces mechanical striking with fluid-based cooling, eliminating impact interference with the powder layer while achieving the desired cooling effect through controlled fluid flow and heat exchange.
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 the control of cooling rates at any layer region, facilitating the development of desired metal structures by accelerating cooling and reducing the time to reach target temperatures, thus overcoming limitations of existing technologies.
Implementation Method 1
the temperature adjustment probe adjusts the temperature of the metal layer or the multilayer structure in the process of being manufactured using the Joule-Thomson effect
Implementation Method 2
one or more temperature measurement probes that measure the temperature of the metal layer or the multilayer structure in the process of being manufactured
Implementation Method 3
one or more temperature adjustment probes that adjust the temperature of the metal layer or the multilayer structure in the process of being manufactured
Data Source
AI summary
One object of the present invention is to provide a multilayer structure manufacturing device and a multilayer structure manufacturing method, which enable control to accelerate the cooling rate in any layer region and facilitates the development of a desired metal structure by controlling the cooling rate. The present invention provides a multilayer structure manufacturing device (1A) including a laser oscillator (14), a chamber (3), a build stage (4) including a powder bed (8) of metal powder M that is movable in the vertical direction in the chamber (3), a plurality of temperature measurement probes (5A, 5B) that measure the temperature of the metal layer or the multilayer structure (20) in the process of being manufactured, and a plurality of temperature adjustment probes (6A, 6B) that adjust the temperature of the metal layer or the multilayer structure (20) in the process of being manufactured, and the temperature measurement probe (5A) and the temperature adjustment probe (5B) are embedded inside the powder bed (5) of the build stage (4).