Laser Cladding Turntable with Segmented Lid for Turbojet Parts
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Solution Overview
Problem
Current methods for laser cladding of aircraft turbojet metal parts, particularly those with curved surfaces, face challenges in preventing oxidation and efficiently covering large areas due to limitations in nozzle movement and gas protection systems, which are either costly or ineffective in eliminating oxidation entirely.
Innovation Solution
A process utilizing a turntable to position metal parts under a lid with a telescopic nozzle opening, allowing for efficient movement of the nozzle and injection of neutral gas to prevent oxidation, enabling quick and complete cladding of multiple metal portions without excessive gas consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a protection chamber with a notch is used to prevent oxidation during laser cladding, then oxidation protection is improved, but the ability to clad curved surfaces over significant distances deteriorates due to limited nozzle movement
Solution Approach 1:
The protection chamber is divided into a fixed base structure and a movable extension component. The extension can be displaced along the curved surface of the part being cladded, allowing the protective atmosphere to follow the geometry while maintaining oxidation protection throughout the cladding process.
Solution Approach 2:
The protection chamber transitions from a static structure to a dynamic system where the extension component can move relative to the fixed base. This movement capability allows the chamber to adapt to curved surfaces and maintain protection during extended cladding operations.
2Productivity
If the notch size is limited to allow gas filling and chamber insertion, then gas protection is improved, but the wall distance becomes too small preventing end movement and complete cladding
Solution Approach 1:
The protection chamber is segmented into a compact base for gas injection and a movable extension that creates additional working space. This segmentation allows the gas protection system to remain efficient while providing sufficient room for the workpiece end to move during cladding operations.
Solution Approach 2:
The extension component adds a new spatial dimension to the protection chamber, extending along the curved surface. This dimensional addition provides the necessary movement space without increasing the base notch size, maintaining gas protection efficiency.
3Object-affected harmful factors
If large booths are used to create protected space, then oxidation protection is improved, but cost and processing time increase due to large quantities of inert gases required
Solution Approach 1:
Instead of protecting the entire work area with inert gas, the protection chamber applies localized protection only to the specific zone where laser cladding occurs. The extension component follows the curved surface to maintain this localized protection, significantly reducing inert gas consumption compared to large booth solutions.
Solution Approach 2:
The protection function is extracted from a large booth system and concentrated into a compact, movable chamber that follows the workpiece. This extraction eliminates the need for large quantities of inert gas while maintaining effective oxidation protection at the cladding location.
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 solution allows for cost-effective, efficient, and rapid cladding of metal parts by maintaining a protective gas environment over the entire surface, reducing oxidation risks and enabling the cladding of complex geometries without the need for large, expensive gas booths.
Implementation Method 1
a nozzle emitting a laser beam or an electron beam that will melt a sprayed powder thus cladding said metal parts to be cladded
Implementation Method 2
inject a neutral gas under the lid
Data Source
AI summary
A process for cladding a metal part of an aircraft turbojet, including a plurality of metal portions, using a nozzle for emitting a laser beam, the process including positioning the metal part to be cladded on a turntable; positioning a cover on the turntable; positioning the nozzle in an aperture present in the cover; introducing an inert gas under the cover; and cladding a first portion of the metal part by carrying out operations of: spraying metal powders; emitting the laser beam; and moving the nozzle relative to the first metal portion.