Laser Cladding Jet Nozzle With Back-Reflection Absorption
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Solution Overview
Problem
Laser cladding processes often result in imperfections such as bonding defects, pores, cracks, and dissolution of hard material particles due to inadequate heat management and interaction with back-reflected radiation, which affect the quality and resilience of the functional layer applied to workpieces.
Innovation Solution
A jet nozzle with a light channel and an outer structure that includes an absorption portion to manage heat and absorb back-reflected radiation, allowing for variable laser beam guidance, powdered filler material application, and independent process zones to enhance welding quality and reduce imperfections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser cladding is performed with conventional jet nozzle design, then laser beam can be conducted to workpiece, but back-reflected radiation damages the laser system and creates imperfections in the functional layer
Solution Approach 1:
The patent applies the 'Blessing in disguise' principle by converting the harmful back-reflected radiation into a beneficial effect. The absorption portion is specifically designed to intercept and absorb the back-reflected laser radiation that would otherwise damage the laser system and create defects in the functional layer. By positioning the absorption portion at the distal end of the light channel, the patent transforms this harmful reflected energy into heat that is dissipated harmlessly, thereby protecting both the laser system and the quality of the deposited functional layer.
Solution Approach 2:
The absorption portion acts as an intermediary element between the laser beam path and the laser system. It intercepts the back-reflected radiation before it can return to damage the laser system or affect the quality of the functional layer. This intermediary structure absorbs the harmful radiation and converts it into heat, which is then dissipated through the nozzle body, thereby protecting the overall system while maintaining the integrity of the laser cladding process.
2Productivity
If laser beam power is increased to improve cladding speed, then productivity increases, but heat management becomes inadequate causing imperfections
Solution Approach 1:
The patent applies the 'Taking out' principle by extracting the heat management function from the traditional nozzle design. The absorption portion is specifically designed to intercept and absorb excess heat from the back-reflected radiation and process zone. By separating this heat absorption function into a dedicated component, the patent enables better thermal management that allows higher laser power to be used for increased productivity without compromising the quality of the functional layer or causing thermal damage.
Solution Approach 2:
The patent applies the 'Parameter changes' principle by modifying the thermal parameters of the nozzle system. The absorption portion changes the heat absorption characteristics of the nozzle by introducing a specialized region with high thermal absorption capacity. This allows the system to handle higher temperatures and laser powers that would otherwise cause imperfections, thereby enabling increased cladding speed and productivity while maintaining temperature control through the absorbed heat being dissipated through the nozzle body.
3Reliability
If absorption portion is added to jet nozzle, then back-reflected radiation is absorbed and welding quality improves, but device complexity increases
Solution Approach 1:
The patent applies the 'Merging' principle by integrating the absorption portion directly into the nozzle body structure. Rather than adding a separate, complex absorption system, the absorption portion is merged with the existing light channel and nozzle geometry. This integration allows the absorption function to be achieved through the nozzle's own structure, minimizing additional complexity while effectively absorbing back-reflected radiation and improving welding quality.
Solution Approach 2:
The absorption portion serves multiple functions simultaneously: it absorbs back-reflected radiation, manages heat from the laser process, and protects the laser system. By designing this single component to perform multiple functions, the patent avoids the need for separate systems for each function, thereby reducing overall device complexity while achieving improved welding quality and system protection.
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
The jet nozzle improves welding quality by reducing bonding defects, pores, and cracks, and prevents the dissolution of hard material particles, thereby increasing the resilience and load-bearing capacity of the functional layer.
Implementation Method 1
The light channel forms an absorption portion for absorbing back-reflected radiation of the at least one laser beam from the workpiece
Data Source
AI summary
A jet nozzle for laser cladding along a direction of advance includes a light channel for conducting at least one laser beam directed onto a workpiece, and an outer structure surrounding the light channel at least in sections. The outer structure extends from a flange portion to a distal region that is formed by a mouth of the jet nozzle from which the at least one laser beam exits. The light channel forms an absorption portion for absorbing back-reflected radiation of the at least one laser beam from the workpiece.