Laser Metal Deposition Pre-Coating for Reflective Metal Substrates

Solution Overview

Problem

Existing metallic substrates with high reflectance, such as copper, suffer from energy loss and reduced coating thickness during laser deposition due to high reflectivity, leading to inadequate protection.

Innovation Solution

A pre-coated metallic substrate with a coating comprising at least one titanate and nanoparticles is applied, which modifies the melt pool physics during laser deposition, enhancing coating penetration and thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a high reflectance metallic substrate (e.g., copper) is used, then the substrate maintains its inherent properties (high reflectance, thermal conductivity), but laser energy is reflected leading to energy loss and reduced coating thickness

Engineering Contradiction:

Improvelaser energy lossVSAvoidcoating thickness

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

A pre-coating layer comprising at least one titanate and at least one nanoparticle is applied to the high reflectance metallic substrate before the main coating deposition. This pre-coating modifies the surface properties to reduce laser reflectance and improve energy absorption, thereby enabling thicker and more precise coating deposition.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The pre-coating layer acts as an intermediary between the laser and the high reflectance metallic substrate. It modifies the interaction by reducing reflectance and enhancing laser energy absorption, which indirectly improves the coating thickness and quality on the underlying substrate.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If a high reflectance metallic substrate is used, then the substrate maintains its inherent properties, but the coating thickness is reduced due to energy loss

Engineering Contradiction:

Improvecoating thicknessVSAvoidlaser energy loss

Core Design Contradiction:

Quantity of substanceVSLoss of energy

Solution Approach 1:

A pre-coating layer comprising at least one titanate and at least one nanoparticle is applied to the high reflectance metallic substrate before the main coating deposition. This pre-coating modifies the surface properties to reduce laser reflectance and improve energy absorption, thereby enabling thicker and more precise coating deposition.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The pre-coating is composed of a composite material system including at least one titanate and at least one nanoparticle. This composite structure provides synergistic effects that optimize both laser energy absorption and coating thickness enhancement.

Inventive Principle:

Principle #40Composite materials

3Productivity

If laser deposition is performed on a high reflectance substrate, then the process can be applied to maintain substrate properties, but deposition efficiency is reduced

Engineering Contradiction:

Improvedeposition efficiencyVSAvoidlaser energy loss

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

A pre-coating layer comprising at least one titanate and at least one nanoparticle is applied to the high reflectance metallic substrate before the main coating deposition. This pre-coating modifies the surface properties to reduce laser reflectance and improve energy absorption, thereby enabling thicker and more precise coating deposition.

Inventive Principle:

Principle #10Preliminary action

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 pre-coating results in a thicker and more protective metallic coating, reducing reflectance and improving deposition efficiency, resulting in enhanced durability.

Implementation Method 1

If the reflectance of the metallic substrate is high, the laser is mainly reflected leading to a loss of energy, a less modified surface and therefore a coating having a lower thickness

Methodology Applied

Scientific EffectLaser absorption: Absorption (EM radiation)

Implementation Method 2

applying the coating in the coating step at least partly by a laser coating process such as laser deposition

Methodology Applied

Scientific EffectLaser metal deposition: Laser

Data Source

PatentUS12509778B2Method for the manufacture of a coated metallic substrate by laser metal deposition

Publication Date: 2025.12.30 ARCELORMITTAL SA

AI summary

A pre-coated metallic substrate wherein a bare metallic substrate having a reflectance higher or equal to 60% at all wavelengths between 0.5 and 5.0 μm is coated with a pre-coating including at least one titanate and at least one nanoparticle; a method for the manufacture of this pre-coated metallic substrate; a method for the manufacture of a coated metallic substrate and a coated metallic substrate.