Laser Rolling Metallic Component Manufacturing
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Solution Overview
Problem
The existing manufacturing processes for metallic components, particularly large and complex components, are energy-intensive, time-consuming, and costly, with high tooling requirements and difficulties in achieving short production lead times due to the need for multiple heat treatments and complex machining, which limits their efficiency and effectiveness.
Innovation Solution
A device and method utilizing a laser light source to heat a support element and substrate to a joining temperature, followed by a rolling process to create a metallic bond between them in a 'cold' state, allowing for the efficient production of large-area or large-volume components in tracks or layers with minimal energy input and tooling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional forging and heat treatment processes are used for large metallic components, then material properties are improved through structure refinement, but production time increases significantly due to multiple intermediate heatings and cooling regimes
Solution Approach 1:
The invention applies laser preheating to specific areas of the workpiece before forging operations. This preliminary thermal action prepares the material in advance for deformation, reducing the need for subsequent extensive heat treatments and cooling cycles, thereby shortening overall production time while maintaining material property improvements
Solution Approach 2:
The invention changes the thermal parameters by using localized laser heating instead of conventional furnace heating. This allows precise control of temperature and heating rate, enabling faster processing cycles while achieving the necessary material temperature for forging operations without requiring prolonged heat treatment regimes
2Stability of the object's composition
If conventional forging processes are used for large components, then structural segregation and pores are reduced, but tooling costs increase significantly due to large and complicated molds
Solution Approach 1:
The invention replaces conventional mechanical forging with a combination of laser heating and rolling. The laser provides the necessary thermal energy for material deformation, while the rolling element applies mechanical pressure. This substitution eliminates the need for complex large-scale forging molds and presses, reducing tooling costs and complexity while maintaining the ability to produce structurally uniform components
Solution Approach 2:
The invention introduces a rolling element as an intermediary between the laser heat source and the workpiece. This rolling element transfers the thermal energy from the laser to the workpiece surface and applies controlled deformation pressure, replacing the need for complex conventional forging tooling while achieving similar structural refinement
3Reliability
If conventional coating techniques are used for surface finishing, then corrosion and wear protection is achieved, but production time increases due to subsequent processing steps
Solution Approach 1:
The invention merges the surface coating process with the main manufacturing process by applying the coating layer during the rolling operation. The coating material is fed onto the workpiece surface and bonded simultaneously with the rolling deformation, eliminating separate coating steps and reducing production time while maintaining corrosion and wear protection
4Speed
If laser heating is used to heat workpiece and support element, then joining temperature is achieved rapidly, but energy input increases compared to conventional methods
Solution Approach 1:
The invention applies laser heating locally to only the areas requiring joining temperature, rather than heating the entire workpiece. The laser beam is directed precisely at the contact zones between the support element and workpiece, providing rapid localized heating with minimal energy input. The rolling element then distributes this localized heat and completes the bonding process
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 approach enables rapid, cost-effective, and energy-efficient production of metallic components with improved material retention and reduced shrinkage stresses, eliminating the need for extensive heat treatment and complex tooling, resulting in shorter production times and higher contour accuracy.
Implementation Method 1
a rectangular or line-shaped laser beam 6, which is emitted by a laser radiation source or laser light source 4, heats both subsequent contact surfaces of the substrate 3 and the support element 1 to suitable joining temperatures
Implementation Method 2
A combination of local deformation at a locally realized deformation temperature occurs in joining processes such as gas and resistance pressure welding
Implementation Method 3
During the rolling, essentially only the two heated surface areas are deformed by the rolling force and are thus firmly connected to one another
Data Source
AI summary
The present invention relates to a device and a method for the adaptive manufacturing of metallic components comprising a substrate (3) and an overlay element (1), which is to be applied to the substrate (3) and to be connected to the substrate (3) in a material-bonded manner, comprising a feeding device (7), which is designed to guide the overlay element (1) onto a surface that is to be coated of the substrate (3), and at least one laser light source (4), with which at least the overlay element (1) can be preheated on the surface thereof by an emitted laser beam (6) directly before or at a point of impingement or an area of impingement between the overlay element (1) and the substrate (3) to a temperature suitable for the material-bonded joining. Also provided is a rolling device (2), which is equipped with at least one roller and is designed to press the heated overlay element (1) onto the substrate (3) and thereby connect it to the substrate (3) in a material-bonded manner. By a transverse movement of the substrate (3) in relation to the feeding device (7) or a movement of the feeding device (7), the overlay element (1) is applied to the substrate (3) in traces or in layers, and so individual traces of the overlay element material are arranged next to one another on the surface of the substrate (3) or layers of the overlay element material are arranged over one another.