Keyhole Wire Laser Additive Manufacturing for Faster Deposition
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Solution Overview
Problem
Laser additive manufacturing methods, particularly wire feeding, face challenges with low energy utilization and deposition efficiency due to high laser energy reflectivity and inefficiencies in forming large parts, which restrict their practical application in fields like aerospace and shipbuilding.
Innovation Solution
A method and system utilizing keyhole effects where a welding wire and laser beam are arranged at specific angles to achieve deep penetration melting, enhancing energy absorption and transfer to the substrate for improved melting rates and formation efficiency, while also using a front wire feeding mode to optimize the angles and positioning for enhanced thermal conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If wire feeding laser additive manufacturing is used to improve material utilization rate, then material waste is reduced, but deposition efficiency remains low due to high laser energy reflectivity
Solution Approach 1:
The patent changes the physical state of the wire surface by introducing oxidation layer or roughening treatment, which fundamentally alters the optical parameters (reflectivity, absorptivity) of the wire surface. This enables the wire to absorb laser energy more effectively, transforming the low deposition efficiency problem into a solvable parameter optimization issue.
Solution Approach 2:
The patent converts the harmful effect of laser energy reflection (which causes low deposition efficiency) into a beneficial effect by intentionally creating an oxidation layer or rough surface on the wire. This layer transforms the reflected energy into absorbed energy, turning the original problem into a solution mechanism.
2Stability of the object's composition
If synchronous powder feeding is used to achieve good compactness, then part density is improved, but energy utilization rate decreases due to laser energy attenuation
Solution Approach 1:
The patent introduces an oxidation layer or rough surface structure as an intermediary between the laser beam and the wire material. This intermediary layer acts as an energy transfer mediator that enhances laser absorption and improves energy utilization efficiency, while the wire feeding mechanism maintains good compactness through controlled deposition.
3Volume of moving object
If traditional laser additive manufacturing methods are used to form large parts, then manufacturing capability is achieved, but processing time increases significantly
Solution Approach 1:
The patent optimizes multiple process parameters simultaneously including laser power, wire feeding speed, and focusing position to achieve high-speed deposition. By changing these parameters and introducing surface treatment methods, the processing speed is significantly increased, reducing the time required to manufacture large parts while maintaining quality.
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 increases the melting rate and formation efficiency of wire feeding laser additive manufacturing, reducing defects like air holes and achieving deposition efficiencies up to triple that of traditional methods, thereby improving material utilization and processing speed.
Implementation Method 1
the laser beam acts on the welding wire and produces a deep penetration melting keyhole. The welding wire absorbs most of the energy of the laser beam and is heated and melted in a deep penetration melting mod
Implementation Method 2
The welding wire absorbs most of the energy of the laser beam
Implementation Method 3
The welding wire transits energy to a surface of the substrate to form a melting pool and a cladding layer
Implementation Method 4
After passing through the welding wire, the laser beam irradiates a second area of the substrate to preheat the second area of the substrate in a thermal conduction mode
Data Source
AI summary
Provided is a method for laser additive manufacturing based on keyhole effects. A welding wire and a laser beam are arranged, at certain angles, on two sides of a normal line of a substrate respectively. The laser beam is applied on the welding wire to generate a deep penetration melting keyhole. The welding wire absorbs energy of the laser beam and is heated and melted in a deep penetration melting mode. The welding wire transmits energy to a surface of the substrate to form a cladding layer. The laser beam irradiates the surface of the substrate after passing through the welding wire, and preheats the surface of the substrate in a heat conduction mode.