Laser Metal Deposition Imaging with Pulsed Illumination
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Solution Overview
Problem
The quality of images captured during laser metal deposition processes is compromised by excessively bright or dark spots and reflections due to the presence of the laser beam, hindering effective monitoring.
Innovation Solution
A laser device with cameras and light sources configured to intermittently illuminate the region of interest with a power higher than blackbody radiation emitted during deposition, allowing for improved image quality and precise monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If cameras are used to monitor the laser metal deposition process, then the monitoring capability is provided, but the image quality is insufficient due to excessively bright or dark spots and reflections from the laser beam
Solution Approach 1:
The patent introduces an intermediary substance (aerosol, gas, or liquid) between the laser beam and the camera to modify the optical path. This intermediary attenuates or scatters the harmful laser reflections and bright spots while allowing the camera to capture the melt pool region, thereby improving image quality without eliminating the laser beam's heating function
Solution Approach 2:
The patent extracts or removes the harmful laser beam interference from the camera's field of view by using optical filters that block specific laser wavelengths. This allows the camera to capture images of the deposition process without the detrimental effects of laser-induced brightness and reflections
2Measurement precision
If continuous illumination with high power light sources is used to improve image quality, then the monitoring precision is improved, but the melting process is influenced and disrupted
Solution Approach 1:
The patent employs periodic or pulsed illumination instead of continuous lighting. The light source is activated only during specific time intervals when images need to be captured, allowing the melt pool to return to its normal thermal state between illumination pulses. This maintains monitoring precision while preventing disruption to the melting process
Solution Approach 2:
The illumination system is made dynamic and adaptive, adjusting its activation timing based on the deposition cycle phase. The light source is synchronized with the deposition process, providing illumination only when the melt pool is in a stable state suitable for imaging, thereby maintaining both monitoring precision and process reliability
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 solution enables more precise and reliable monitoring of the laser metal deposition process by obtaining high-quality images without interfering with the melting process, facilitating adjustments such as alignment and parameter optimization.
Implementation Method 1
a laser beam source configured to fuse the metallic feedstock with the substrate by emitting a laser beam of a first power
Implementation Method 2
a power of a blackbody radiation emitted during laser metal deposition
Implementation Method 3
one or more light sources configured to intermittently illuminate the region of interest with a second power higher than a power of a blackbody radiation
Data Source
AI summary
The present disclosure relates to laser devices for laser metal deposition and methods for laser metal deposition. A laser device for laser metal deposition on a substrate is disclosed. The laser device comprises: a delivery opening for delivering a wire or powder metallic feedstock to the substrate; a laser beam source configured to fuse the metallic feedstock with the substrate, the laser beam source being configured to emit a laser beam of a first power; a plurality of cameras configured to record images of a region of interest; and one or more light sources configured to illuminate the region of interest. The one or more light sources are configured to illuminate with a power of a blackbody radiation emitted during laser metal deposition.