Flexible Tool Thermal Shock Cleaning for Internal Powder Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for removing conglomerated powder from internal passages of additively manufactured components, such as those produced by Electron Beam Melting, are inefficient, as they often fail to effectively dislodge and extract partially sintered material from complex geometries like non-line of sight passages.
Innovation Solution
A tool with a flexible section and a head equipped with a fiber optic laser emitter and a nozzle for ejecting cooling fluids like liquid nitrogen or helium is used to deliver rapid thermal shocks, inducing sufficient CTE differential strain to fracture weak bonds between partially sintered metal particles, facilitating the removal of conglomerated powder through spiral grooves and air jets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional removal methods (accelerated media blast, mechanical scraping, ultrasonic vibration) are used to remove conglomerated powder from internal passages, then some powder removal is achieved, but the removal efficiency is low and the method is ineffective for complex geometries
Solution Approach 1:
The invention changes the physical state and temperature parameters of the cooling fluid to create extreme thermal conditions. By delivering rapid thermal shocks through alternating heating (laser) and cooling (liquid nitrogen/helium), the system induces thermal expansion and contraction that fractures the conglomerated powder, dramatically improving removal effectiveness from internal passages including complex geometries
Solution Approach 2:
The system employs periodic alternating action between the laser emitter and cooling fluid ejection. The laser heats the powder for a brief period, then the cooling fluid is ejected to rapidly cool it, creating repeated thermal cycling. This periodic thermal shock mechanism progressively fractures and loosens the conglomerated powder, enabling efficient removal without damaging the component
2Ease of manufacture
If repeated accelerated media blast and mechanical scraping are used to remove powder, then some surface powder is removed, but powder within internal passages remains trapped and difficult to access
Solution Approach 1:
The invention extracts the cleaning mechanism directly into the internal passages by using a flexible delivery system that can navigate complex geometries. The laser and cooling fluid are delivered through a flexible hose directly to the powder location inside the passages, extracting the cleaning action from external surface-only methods to internal direct-action methods, enabling complete powder removal
Solution Approach 2:
The invention replaces mechanical scraping and media blasting with a thermal field-based cleaning mechanism. Instead of using mechanical contact or projectile impact, the system uses laser heating and rapid cooling to induce thermal stress that fractures the powder, substituting mechanical removal with thermal-field-induced removal that can access internal passages
3Strength
If ultra-sonic or ultrasonic vibratory methods are used to liberate powder particles, then some loose powder is removed, but conglomerated powder within internal passages remains difficult to dislodge
Solution Approach 1:
The invention changes the physical parameters applied to the powder from mechanical vibration to extreme thermal parameters. By creating rapid temperature changes through laser heating and cryogenic cooling, the system induces thermal expansion and contraction that generates stress exceeding the bond strength of conglomerated powder, effectively fracturing it without requiring mechanical vibration
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 enables direct and rapid removal of conglomerated powder from internal passages, effectively addressing the inefficiencies of existing techniques by inducing thermal fractures and transporting debris out of complex geometries.
Implementation Method 1
an emitter within the head; wherein the emitter includes a fiber optic laser
Implementation Method 2
delivering a series of thermal shocks with a tool to a conglomerated powder within an internal passage
Implementation Method 3
inducing sufficient internal CTE (Coefficient of Thermal Expansion) differential strain to fracture the weak bonds between partially sintered metal particles
Implementation Method 4
operation of the emitter and ejection of the cooling fluid alternate; alternating operation of the emitter and ejection of a cooling fluid thereby delivering the series of thermal shocks
Implementation Method 5
an air jet within the head; transporting the conglomerated powder out of the internal passage along spiral grooves in the tool
Data Source
AI summary
A tool includes a head that extends form the flexible section, an emitter within the head; and a nozzle to eject a cooling fluid therefrom. A method of additively manufacturing a component including delivering series of thermal shocks to a conglomerated powder within an internal passage of an additively manufactured component to facilitate removal of the conglomerated powder.