Nickel-Based Laser Cladding Powder for Low-Porosity Glass Molds
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Solution Overview
Problem
Existing methods for resurfacing glassware molds, such as torch surfacing and Plasma Transferred Arc (PTA), are labor-intensive, variable in results, and can alter the thermal and mechanical properties of the mold, while laser cladding faces challenges with porosity and uniformity of the deposited metal alloy due to rapid solidification and unstable powder flow.
Innovation Solution
A nickel-based metal powder with a specific particle size distribution and composition, including at least 90% nickel, chromium, boron, and silicon, is used for laser cladding, which improves metallurgical quality and robustness by controlling porosity and ensuring a stable, uniform flow during deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If torch-based cladding is used to fuse metal alloy onto mold surfaces, then the mold can be repaired and extended service life, but the operator experiences physical strain and there is significant variability in results
Solution Approach 1:
The patent replaces manual torch-based cladding with automated laser cladding technology. The laser beam provides precise, consistent heating without manual intervention, eliminating operator physical strain and ensuring uniform cladding results through automated control of power, speed, and positioning.
Solution Approach 2:
The patent changes the heating method from flame-based (torch) to laser-based energy delivery. This parameter change enables precise control of thermal input, consistent melting depth, and reproducible cladding quality, resolving the variability issue while maintaining repair capability.
2Speed
If Plasma Transfer Arc (PTA) cladding is used to heat the mold surface, then the heating speed increases and the heat-affected zone is limited, but the mold must be preheated to 350°C and requires several hours of step-by-step cooling
Solution Approach 1:
The patent replaces PTA plasma arc heating with laser beam heating. The laser provides comparable high heating speed with even more localized energy delivery, eliminating the need for extensive preheating and prolonged cooling cycles while maintaining rapid melting capability.
Solution Approach 2:
The laser beam delivers energy to a highly localized area, creating a concentrated heat source that melts only the necessary cladding zone without requiring bulk preheating of the entire mold. This local heating approach eliminates the time-consuming preheating and step-by-step cooling requirements of PTA.
3Productivity
If metal powder is deposited onto the machined surface and fused using a laser beam, then the resurfacing process is rapid and applicable to all mold types, but the rapid solidification causes significant porosity in the cladding bead
Solution Approach 1:
The patent modifies the metal powder characteristics (particle size distribution, composition) and adjusts laser parameters (power, speed, focus position) to control the melting and solidification process. These parameter changes reduce porosity formation while maintaining rapid solidification benefits for high productivity.
Solution Approach 2:
The patent uses specifically formulated metal powder compositions with controlled particle size distributions and chemical compositions. This composite approach to material design ensures optimal flow characteristics and melting behavior that minimize porosity while maintaining rapid processing capability.
4Productivity
If the metal powder flow rate changes during deposition, then the laser power applied to the surface changes, but the weld bead quality becomes non-uniform across the cladding surface
Solution Approach 1:
The patent implements feedback control systems that monitor powder flow rate and laser parameters in real-time. When deviations are detected, the system automatically adjusts parameters to maintain consistent weld bead quality, ensuring uniform cladding across the entire surface while allowing flexible deposition rates.
Solution Approach 2:
The patent uses dynamically adjustable powder delivery systems and laser parameters that can adapt during the cladding process. This dynamic control ensures that even when deposition rates vary, the resulting weld bead maintains uniform quality through real-time parameter optimization.
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 nickel-based metal powder enhances the mechanical and thermal resistance of the mold, reduces porosity, and maintains uniformity of the deposited bead, improving the overall quality and durability of the resurfacing process.
Implementation Method 1
the melting of the material deposited on the surface to be cladding is carried out by means of a laser beam
Implementation Method 2
depositing metal powder onto the machined surface, and fusing the powder onto the machined surface
Data Source
Figure 1
AI summary
The present invention relates to a nickel-based metal powder for laser cladding of a glass mold, said metal powder comprising at least 90% by mass of nickel, chromium, boron, and silicon. Furthermore, the metal powder comprises at most 0.025% by mass of oxygen.