Device and method for electromagnetic induction heating-assisted laser additive manufacturing of titanium matrix composite
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Solution Overview
Problem
Existing laser additive manufacturing technologies face issues with residual stress, cracking, and uneven temperature distribution, particularly in the formation of titanium matrix composites, due to high cooling rates and temperature gradients, which are not effectively addressed by previous methods that focus on preheating substrates rather than synchronously heating and cooling specific areas during the process.
Innovation Solution
A device and method that synchronously moves an electromagnetic induction coil and laser head to provide real-time preheating and slow cooling, reducing temperature gradients and thermal stress, using an infrared thermometer for temperature control and implementing temperature-gradient preheating to minimize coarse microstructure formation and enable on-line annealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If substrate preheating is used in selective laser melting, then preheating temperature and efficiency are improved, but heating uniformity deteriorates as the forming platform descends and distance between top layer and coils increases
Solution Approach 1:
The patent employs a movable induction heating device that dynamically adjusts its position to maintain a constant distance from the top layer of the forming platform during the entire additive manufacturing process. This dynamic positioning ensures uniform electromagnetic induction heating throughout the process, preventing temperature field non-uniformity that would otherwise occur as the platform descends.
Solution Approach 2:
The patent introduces a movable induction heating device as an intermediary between the substrate and the top layer, which can adjust its position to provide consistent heating. This intermediary device bridges the gap between the stationary heating source and the moving forming platform, ensuring uniform heat distribution.
2Productivity
If high cooling rate is used in laser manufacturing, then manufacturing speed is improved, but residual stress and cracking increase
Solution Approach 1:
The patent applies preliminary induction heating to the substrate and deposited layers before laser melting occurs. This preheating action raises the baseline temperature of the workpiece, which subsequently reduces the cooling rate after laser processing. The preliminary thermal preparation prevents rapid cooling that would otherwise cause residual stress and cracking, while still maintaining efficient manufacturing speeds.
Solution Approach 2:
The patent changes the thermal parameters of the manufacturing process by superimposing induction heating on the laser processing. This parameter modification alters the cooling rate and temperature gradient, transforming the process from high-speed but high-stress manufacturing to a balanced process that maintains productivity while reducing cracking susceptibility.
3Use of energy by moving object
If uneven temperature distribution is used in laser processing, then energy efficiency is improved, but residual stress increases
Solution Approach 1:
The patent merges two different heating methods - electromagnetic induction heating and laser heating - into a single integrated process. The induction heating provides uniform background heating to reduce thermal gradients, while the laser provides localized energy for melting and deposition. This combination allows the system to maintain laser energy efficiency for material processing while using induction heating to manage overall temperature distribution and minimize residual stress.
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 significantly reduces residual stress and cracking tendencies, improves mechanical performance, and enhances the efficiency of laser deposition by allowing precise control over heating and cooling, resulting in higher quality titanium matrix composite samples with reduced defects.
Implementation Method 1
a coil and a laser head do synchronous movement to implement small-area real-time preheating and slow cooling on the deposition sample
Implementation Method 2
one small coil preheats the substrate or the deposition sample, and the other small coil slowly cools a solidification area behind the molten pool
Implementation Method 3
laser additive manufacturing of a titanium matrix composite
Implementation Method 4
an infrared thermometer detects the temperature of the molten pool in real time
Data Source
AI summary
The present invention provides a device and method for electromagnetic induction heating-assisted laser additive manufacturing of a titanium matrix composite and belongs to the technical field of laser additive manufacturing. The device includes a coaxial-powder feeding laser deposition system and an electromagnetic induction heating synchronous auxiliary system. The coaxial-powder feeding laser deposition system includes a substrate, a deposition sample, a laser head and an infrared thermometer. The electromagnetic induction heating synchronous auxiliary system includes an electromagnetic induction power supply auxiliary unit, a coil, a steering heightening mechanism, a driven shaft and a transverse sliding groove. The coil is connected to an output end of the electromagnetic induction power supply auxiliary unit. The coil and the laser head do synchronous movement to implement small-area real-time preheating and slow cooling on the deposition sample.