Laser Cladding Smoothing for Machinable Repair Surfaces
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Solution Overview
Problem
Laser cladding processes result in hard, irregular surfaces that are difficult to machine, limiting their application in repairing components like tappets, which require precise machining, and leading to premature scrapping instead of repair.
Innovation Solution
A method involving laser cladding followed by a smoothing operation using a second laser beam at a lower power level after cooling the additive layer to a reduced temperature, improving the machinability of the surface by creating a smoother, more durable layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If laser cladding is used to add material to part surfaces, then material can be added to restore worn surfaces, but the resulting surface is hard and irregular making machining difficult or impossible
Solution Approach 1:
The patent applies a two-stage laser process with different parameters: first a high-power laser for cladding, then a low-power laser for surface smoothing. This parameter change transforms the hard, irregular cladded surface into a smoother, more machinable surface while preserving the added material
Solution Approach 2:
The patent introduces an intermediary smoothing step between laser cladding and final machining. This intermediary process uses a second laser beam to create a transition surface that is neither as rough as the raw cladded surface nor requires aggressive machining, thereby protecting machining inserts and enabling further machining operations
2Ease of repair
If laser cladding is used to repair components like tappets, then material can be restored to worn areas, but the irregular surface causes machining inserts to chip instantly requiring replacement
Solution Approach 1:
The patent performs a preliminary surface smoothing operation immediately after laser cladding while the part is still in the additive manufacturing system. This preliminary action prepares the surface before it is removed for final machining, preventing the irregular surface from damaging machining inserts in subsequent operations
3Device complexity
If traditional laser cladding is used without smoothing, then the process is simple and direct, but the surface cannot meet tolerance requirements for precision components
Solution Approach 1:
The patent merges two previously separate processes (laser cladding and laser surface treatment) into a single integrated system. The smoothing laser is incorporated into the additive manufacturing system, allowing both cladding and surface preparation to be performed in one setup, thereby achieving precision requirements without significantly increasing overall process complexity
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
Enables the repair and reuse of components like tappets by enhancing the machinability of laser cladded surfaces, allowing for the restoration of worn surfaces to specified tolerances, reducing waste and costs.
Implementation Method 1
forming the substrate material into an additive layer on top of the surface by exposing the substrate material to a first laser beam having a first power level
Implementation Method 2
cooling the additive layer from a first temperature reached at the completion of the forming step to a second temperature
Implementation Method 3
exposing the additive layer to a second laser beam having a second power level. The second power level can be lower than the first power level
Data Source
AI summary
A method of additive manufacturing includes providing a substrate material at a location proximate a surface of a part and forming the substrate material into an additive layer on top of the surface by exposing the substrate material to a first laser beam having a first power level. After forming the additive layer on the part, the method includes cooling at least a portion of the additive layer from a first temperature reached at the completion of the forming step to a second temperature. After cooling, the method includes exposing the additive layer to a second laser beam having a second power level, wherein the second power level is lower than the first power level.