Localized Inert Gas Shielding for Laser Cladding of Large Metal Parts
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Solution Overview
Problem
Current laser cladding and forming methods for metals like titanium alloys require expensive and limited inert atmosphere chambers, restricting the size of components that can be formed and making it difficult to move the system for on-site repairs.
Innovation Solution
A method involving a focused laser beam and coaxial inert carrier gas to create a partial atmosphere protection by forming inert protective gas layers around the metal or alloy powder beam, using gases like helium and argon to prevent oxidation, with adjustable parameters for thickness, flow rate, and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a full inert atmosphere chamber is used to protect metal molten pools from oxidation, then the reliability of the cladding layer is improved, but the device complexity and cost increase significantly
Solution Approach 1:
The patent applies local quality by creating a localized inert atmosphere only at the laser processing position using a gas guide component, rather than filling the entire chamber with inert gas. The gas guide directs inert gas flow precisely to the molten pool area, providing protection where needed while avoiding the complexity and cost of a full chamber atmosphere control system.
Solution Approach 2:
The patent extracts the essential protective function from the complete inert atmosphere chamber and isolates it to a localized gas guide component. This separates the critical protection function (preventing oxidation at the molten pool) from the unnecessary complexity of maintaining a full chamber atmosphere, allowing the system to achieve reliability without the burden of a complex atmosphere chamber.
2Volume of moving object
If a large inert atmosphere chamber is used to form large-sized components, then the manufacturing capability is improved, but the device complexity and cost increase
Solution Approach 1:
The patent extracts the protective atmosphere function from a large chamber structure and concentrates it in a compact gas guide component that moves with the laser beam. This allows large components to be processed without requiring a proportionally large atmosphere chamber, as protection is delivered locally at the processing position regardless of component size.
Solution Approach 2:
The patent introduces dynamics by making the inert gas protection mobile through the gas guide component that moves with the laser beam, rather than using a static large chamber. This dynamic approach allows the system to adapt to large components of various sizes without requiring a fixed large chamber structure.
3Reliability
If a fixed inert atmosphere chamber is used to protect the processing area, then the reliability is improved, but the ease of operation decreases due to inability to move for on-site repair
Solution Approach 1:
The patent extracts the protective atmosphere function from a fixed chamber and relocates it to a mobile gas guide component that travels with the laser beam. This allows the system to maintain reliable protection while being easily movable to different locations for on-site repair and fabrication.
Solution Approach 2:
The patent transforms the static atmosphere chamber into a dynamic system where the gas guide component moves with the laser beam to the required position. This dynamic configuration maintains protection effectiveness while enabling mobility and flexibility for on-site operations.
4Reliability
If a thick inert protective gas layer is used to ensure complete protection, then the reliability is improved, but the loss of substance increases due to higher gas consumption
Solution Approach 1:
The patent applies local quality by directing inert gas flow precisely to the molten pool area through the gas guide component, creating a concentrated protective atmosphere only where oxidation protection is needed. This localized approach provides reliable protection while minimizing inert gas consumption compared to filling a large chamber with thick protective gas.
Solution Approach 2:
The patent uses partial action by providing inert gas protection only at the critical molten pool position rather than throughout the entire chamber. This selective approach achieves sufficient protection reliability with reduced gas consumption, avoiding the excessive gas use that would result from thick protective gas layers in a large chamber.
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 allows for convenient, fast, and economical on-site forming and repair of large components by creating a localized inert environment, reducing costs and size limitations while preventing oxidation during the process.
Implementation Method 1
transporting a metal or alloy powder beam by an inert carrier gas to move on a machined surface with a focused laser beam
Implementation Method 2
forming at least one layer of inert protective gas at the outer periphery of the metal or alloy powder beam
Data Source
AI summary
The present invention relates to a method for laser cladding and forming of a metal or alloy under partial atmosphere protection. Including: transporting a metal or alloy powder beam by an inert carrier gas to move on a machined surface with a focused laser beam; and forming at least one layer of inert protective gas at the outer periphery of the metal or alloy powder beam. The inert protective gas includes first inert protective gas, and the first inert protective gas is at the outer periphery of the focused laser beam. The problems of limited size, high cost and difficulty in moving a cladding and forming system and the like during part forming are solved by forming the inert protective gas at the outer periphery of the focused laser beam. Compared with the prior art, the convenient, fast and economical method is provided for on-site part forming and repair.