Laser Powder Nozzle Layout for Thermal Gradient Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing processes using laser fusion of metal powders face challenges with non-uniformity, porosity, and microfractures due to uncontrolled temperature gradients and limited control over energy profiles, leading to poor quality and structural integrity of the produced objects.
Innovation Solution
A laser operating machine with a movable structure and rotatable nozzles that allows for independent control of laser beam orientation and nozzle inclination, enabling precise energy profile management during pre-heating, fusion, and post-heating phases to minimize temperature gradients and prevent nozzle interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If laser fusion is used to manufacture objects via additive manufacturing, then complex geometrical shapes can be produced, but uncontrolled temperature gradients cause microfractures and cracks that compromise structural integrity
Solution Approach 1:
The patent applies preliminary action by implementing pre-heating treatment before the main fusion process. The laser applies controlled thermal treatment to the substrate and powder bed beforehand, raising the temperature to reduce thermal gradients during subsequent fusion, thereby preventing microfractures and cracks while enabling complex geometries to be produced with improved structural integrity
Solution Approach 2:
The patent implements parameter changes by dynamically adjusting laser power, scanning speed, and hatching patterns throughout the manufacturing process. The system modifies these parameters based on real-time conditions to maintain optimal temperature gradients, preventing thermal stress-induced fractures while preserving the ability to create complex geometrical shapes
2Manufacturing precision
If the laser beam is displaced within a frame to enable different energy profiles, then pre-heating and post-heating control is improved, but the frame and nozzles interfere with the laser beam and limit orientation freedom
Solution Approach 1:
The patent resolves the interference problem by moving the laser source to a different spatial dimension - specifically, positioning it on the moving element itself rather than on a fixed frame. This allows the laser to approach the workpiece from above without interference from nozzles or frame structures, enabling complete orientation freedom while maintaining precise energy profile control for pre-heating, fusion, and post-heating phases
Solution Approach 2:
The patent applies segmentation by separating the laser beam generation and delivery functions from the nozzle assembly. The laser source is independently positioned on the moving element, allowing independent optimization of laser trajectory and nozzle positioning without mutual interference, thus achieving both precise energy profile control and full adaptability in beam orientation
3Adaptability or versatility
If the relative position and orientation between deposition path and nozzles change along the path, then obstacles can be avoided, but deposition quality and quantity are affected
Solution Approach 1:
The patent implements dynamics by making the nozzle assembly rotatable about a vertical axis, allowing real-time adjustment of nozzle orientation and position relative to the deposition path. This dynamic positioning enables the nozzles to avoid obstacles while maintaining optimal alignment with the laser beam and substrate, preserving deposition quality and quantity despite changes in relative position along the path
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
Enhances the quality and structural integrity of laser-fused objects by improving uniformity, reducing porosity, and preventing fractures through advanced control of thermal treatment processes.
Implementation Method 1
an optical laser assembly for conveying a laser beam to form a laser spot focused on said working substrate in order to carry out thermal treatment on said powders
Implementation Method 2
conveying a laser beam to form a laser spot focused on said working substrate
Implementation Method 3
additive manufacture of objects via a process of laser thermal treatment of metal powders, in particular via fusion
Implementation Method 4
laser thermal treatment of metal powders
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A laser operating machine for additive manufacture of objects, via a process of laser thermal treatment of metal powders, in particular via fusion, comprising a movement structure (11), which is mobile in a working space (100) that comprises a working surface (110), said machine operating according to a first cartesian system of axes of movement (X, Y, Z) and being configured for supporting a moving element (12) comprising one or more nozzles (34) for emitting jets of powder to be treated thermally onto a working substrate (100, 110), and an optical laser assembly (20) for conveying a laser beam (L) to form a laser spot (S) focused on said working substrate (100, 110) in order to carry out thermal treatment of said powders. According to the invention, said moving element (12) comprises: an upper portion (12a) associated in a fixed way to said movement structure (11), said optical laser assembly (20) being set in said upper portion (12a); and a lower portion (12b), set in which is a tool- carrier frame (30), arranged on which are said one or more nozzles (34) for emitting jets of powder, and in that said nozzles (34) are arranged on said frame (30) so that longitudinal axes (U) thereof form an angle of inclination (β) with respect to said vertical axis (I) such that jets (PJ) of said nozzles (34) intersect in a powder-deposition point (PD), said machine (10) comprising actuator means for varying said angle of inclination (β) of said longitudinal axes (U) of said one or more nozzles (34); said optical laser assembly (20) being set in the moving element (12) so as to send the laser beam (L) onto the working surface (110) passing within perimeter defined by said plurality of nozzles (34) emitting jets of powder.