Laser Hybrid Additive Manufacturing for Precision Microchannels
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Solution Overview
Problem
Selective Laser Melting technologies face challenges in achieving high precision, high finish, and high cleanliness for aerospace key parts, particularly in forming microchannels and overhang surfaces, with issues like powder residue and insufficient processing capabilities for microchannels.
Innovation Solution
An all-laser hybrid additive manufacturing method combining selective laser melting, laser precision removal, and laser precision packaging, using a continuous wave infrared laser for selective laser melting and a pulse laser for etching and packaging to form microchannels, with a prefabricated plate welded to create a microchannel structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If selective laser melting is used to form complex structural parts, then the ability to create complex geometries is improved, but the manufacturing precision and surface finish deteriorate
Solution Approach 1:
The patent combines selective laser melting (additive) with laser precision removal (subtractive) in a hybrid manufacturing system. The additive process builds complex geometries while the subtractive process refines surfaces and creates precise microchannels, resolving the contradiction between geometric complexity and manufacturing precision
Solution Approach 2:
The patent introduces an intermediary processing step using laser precision removal between additive manufacturing stages. This intermediary subtractive process removes powder residue, improves surface finish, and creates precise microchannels, acting as a mediator between the additive process and final product requirements
2Manufacturing precision
If addition and subtraction materials are introduced in additive manufacturing to improve macro-scale finish, then the surface finish is improved, but the reliability and durability of the tool deteriorate
Solution Approach 1:
The patent replaces mechanical tool-based subtraction with laser-based precision removal. The laser beam acts as a contactless tool that removes material and powder residue without mechanical wear, maintaining high reliability and durability while achieving improved surface finish and microchannel precision
3Manufacturing precision
If ultra-fast laser subtractive technology is introduced to realize precision forming of microchannels, then the processing capability for microchannels is improved, but powder residue and powder adhesion problems worsen
Solution Approach 1:
The patent converts the harmful effect of laser-induced powder adhesion into a beneficial process by using controlled laser heating to melt and seal powder residue within the microchannel structure. The same laser energy that causes powder adhesion is subsequently used to fuse the powder into the channel walls, eliminating residue and improving cleanliness
4Ease of manufacture
If conventional methods are used for manufacturing aerospace key parts, then the production process is simplified, but the high smoothness, high cleanliness, and high precision requirements are not met
Solution Approach 1:
The patent employs a universal laser system that performs multiple functions: additive manufacturing, surface melting for smoothness, precision removal for microchannels, and powder residue elimination. This multi-functional approach meets high smoothness, cleanliness, and precision requirements while maintaining process integration and relative simplicity
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 method achieves high precision, high finish, and high cleanliness in forming microchannels and overhang surfaces, addressing the limitations of existing technologies by integrating both additive and subtractive processes with laser precision packaging.
Implementation Method 1
performing selective laser melting by a laser I to obtain a matrix of a metal material
Implementation Method 2
performing selective laser melting by a laser I to obtain a matrix of a metal material
Implementation Method 3
etching the matrix obtained in step a) by a laser II to form a groove structure, wherein the laser II is a pulse laser
Implementation Method 4
welding and packaging the prefabricated plate by the laser I to form a microchannel
Data Source
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AI summary
Disclosed is a method for an all-laser hybrid additive manufacturing. After a matrix is obtained by means of selective laser melting forming, a subtractive forming is carried out on the matrix by means of a pulse laser to form a cavity, and the cavity is then packaged to obtain a forming material with an internal cavity structure. A laser precision packaging method is used in the method based on the melting of the laser selective region. Also disclosed is the apparatus, comprising a laser unit (2), a control unit (4) and a forming unit (6). The laser unit is in light path connection with the forming unit, and the control unit is electrically connected with the laser unit and the forming unit respectively. The laser unit comprises a first laser light source and a second laser light source. The forming unit comprises a welding unit (68), and the welding unit is controlled by the control unit and is matched with the laser unit for the additive manufacturing.