Laser Cladding with Annular Beam Segmentation for Independent Heating
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Solution Overview
Problem
Existing laser cladding methods face inefficiencies in energy usage and accuracy due to the inability to separate the heating of deposited material and the workpiece, leading to significant energy loss and reduced precision.
Innovation Solution
A method and device that form a series of parallel annular laser beams with adjustable power distribution, transformed into conical beams for separate focusing on the workpiece and cladding material, allowing for independent heating and efficient energy use through a system including a laser, conical mirrors, and a rotating mirror for gas and material feeding, with options for multipass radiation and wavelength conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a single circular laser beam is used for laser cladding, then the device structure is simple, but the heating of deposited material and workpiece cannot be separated leading to energy loss and reduced accuracy
Solution Approach 1:
The single circular laser beam is segmented into multiple annular beams using a diffractive optical element. This segmentation allows different regions of the beam to be focused at different positions along the optical axis, enabling separate heating zones for the workpiece and deposited material, thereby reducing energy loss while maintaining reasonable device complexity
Solution Approach 2:
The invention transitions from a two-dimensional circular beam profile to a three-dimensional structured beam pattern with multiple annular rings at different focal depths. This dimensional transformation enables spatial separation of heating zones along the optical axis, allowing independent temperature control for the workpiece surface and the deposited material
2Manufacturing precision
If a single circular laser beam is used for laser cladding, then the device structure is simple, but the cladding accuracy is reduced due to inability to separately heat deposited material and workpiece
Solution Approach 1:
The laser beam is divided into multiple annular segments that can be independently focused at different positions. This segmentation enables precise control over where heat is applied - one annular beam focuses on the workpiece surface while another focuses on the deposited material, thereby improving cladding accuracy
Solution Approach 2:
Different regions of the laser beam are assigned different focal positions and power distributions to create localized heating zones with optimal temperature profiles for specific purposes - one zone for workpiece heating and another for deposited material heating, ensuring high cladding quality
3Loss of energy
If multiple annular beams with different focal positions are used, then separate heating of workpiece and deposited material is achieved, but the optical system complexity increases
Solution Approach 1:
The diffractive optical element automatically generates multiple annular beams with different focal positions from a single input laser beam. The system self-organizes the beam structure to create the required multi-focal pattern without requiring complex external optical components, thereby improving energy efficiency while limiting optical system complexity growth
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 reduces energy consumption, enhances cladding accuracy, and improves the quality of manufactured parts by optimizing thermal processing conditions and redistributing laser power for precise heating.
Implementation Method 1
applying weld material in the focal region of the laser beam disposed on the surface of the workpiece
Data Source
AI summary
A method and device for laser cladding by independently heating the cladding material and the surface of the workpiece consist in formation of the series of parallel annular laser beams, possibly different wavelengths, with an adjustable distribution of laser radiation power across the annular beams. The annular beams are transformed into a series of conical beams which are separately focused along a single optical axis, along which the cladding material is fed. The device can be supplemented with a cylindrical mirror for the multipass laser radiation through the stream of cladding material with the possibility of the laser radiation return to the laser resonator.