Ultra-High-Speed Laser Cladding for Flat Plate Additive Manufacturing
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Solution Overview
Problem
Ultra-high-speed laser cladding technologies are limited to cylindrical surfaces and have low cladding speeds for flat plates, requiring advancements in processing precision and defect control for effective additive manufacturing.
Innovation Solution
An apparatus and method for ultra-high-speed laser cladding on flat plates, utilizing a laser generator, beam expander, reflector, and ultrasonic vibration platforms, with a closed-loop feedback control system for precise powder feeding and dynamic control of laser energy, enabling high-speed cladding and defect repair on flat surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional laser cladding technology is used on cylindrical surfaces with rotation, then ultra-high cladding speed can be achieved, but the technology is limited to cylindrical surfaces and cannot effectively process flat plates
Solution Approach 1:
Instead of rotating the workpiece (cylindrical surface approach), the invention inverts the approach by keeping the workpiece stationary and rotating the laser cladding head assembly. This allows the same rotational mechanism to effectively process both cylindrical and flat surfaces, achieving ultra-high cladding speeds on flat plates while maintaining versatility across different surface types.
Solution Approach 2:
The laser cladding head assembly is designed with multi-functional capabilities to process both cylindrical and flat surfaces. By integrating the rotational mechanism with the laser cladding head rather than the workpiece, the system achieves universal applicability across different geometries while maintaining high productivity on flat plates.
2Productivity
If high-speed laser cladding is implemented on flat plates, then processing efficiency improves, but processing precision and defect control become more challenging
Solution Approach 1:
The system incorporates real-time feedback mechanisms that monitor the cladding process parameters and adjust them dynamically. This feedback control enables the system to maintain processing precision and defect control even at ultra-high cladding speeds on flat plates by continuously optimizing laser power, powder feed rate, and head rotation speed based on actual process conditions.
Solution Approach 2:
The laser cladding head assembly uses dynamic control of rotation speed and laser parameters during the process. By making the system dynamic and adaptable rather than static, the invention maintains manufacturing precision while achieving high productivity on flat plates through real-time parameter adjustment.
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
Achieves high-speed cladding on flat plates up to 100 m/min, improves processing efficiency, reduces defects, and extends two-dimensional additive manufacturing to three-dimensional capabilities, enhancing the performance and precision of produced parts.
Implementation Method 1
a laser generator, a beam expander, and a reflector... focusing a laser outputted from the laser generator onto the surface of the matrix
Implementation Method 2
a plurality of ultrasonic vibration platforms are arranged on the rotary platform... each of the ultrasonic vibration platforms is configured to rotate on the rotary platform
Implementation Method 3
The cladding nozzle is connected to a powder pool through a hose and a pump in succession... controlling the pump to start operating, to spray a powder from the powder pool to the surface of the matrix through the cladding nozzle
Data Source
AI summary
The present invention relates to an apparatus and method for additive manufacturing by ultra-high-speed laser cladding. The apparatus includes a laser generator, a beam expander, and a reflector. A light exit path of the reflector is arranged facing a cladding nozzle. The cladding nozzle is connected to a powder pool through a hose and a pump in succession. A matrix is arranged below the cladding nozzle. The matrix is located on a rotary platform. A main stepping motor is fixedly mounted below the rotary platform. The main stepping motor is fixed on a lifting platform. A laser rangefinder is arranged above the matrix. During the laser cladding-based additive manufacturing process, the ultrasonic vibration device, the infrared camera, the high-speed camera, the laser rangefinder, and the radiological inspection system are turned on to monitor the laser cladding process in real time.