Laser Surface Treatment for Heat-Affected Layer Removal
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Solution Overview
Problem
Existing methods for removing the laser-heat-affected layer, such as those described in Japanese Unexamined Patent Publication No. 2015-533973, are complicated and inefficient, requiring multiple processes including grid blasting, chemical etching, and mechanical finishing.
Innovation Solution
A surface treatment method involving irradiation with a pulsed laser beam through a transparent liquid and causing particles with a core made of an elastic body and abrasive grains to collide with the heat-affected layer, utilizing microcracks or pinholes as starting points to efficiently remove the layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple processes (grid blasting, chemical etching, mechanical finishing) are used to remove the heat-affected layer, then the heat-affected layer can be removed, but the process becomes complicated and inefficient
Solution Approach 1:
The patent combines multiple removal processes (blasting and chemical etching) into a single integrated process where particles with elastic cores and abrasive grains perform both mechanical impact and chemical etching functions simultaneously, eliminating the need for separate processing steps
Solution Approach 2:
The particles are designed with dual functionality: the elastic core provides mechanical impact to create microcracks while the abrasive grains on the surface perform chemical etching, allowing a single material to perform multiple removal mechanisms that previously required separate processes
2Manufacturing precision
If multiple processes are used to remove the heat-affected layer, then complete removal can be achieved, but the treatment time increases
Solution Approach 1:
The particles continuously perform both mechanical impact and chemical etching in a single ongoing process without interruption or transition between separate operations, maintaining useful action throughout the treatment duration and eliminating idle time between processes
3Productivity
If particles collide with the heat-affected layer to remove it, then the layer can be removed efficiently, but the influence of collision may extend to the inside of the heat-affected layer
Solution Approach 1:
The particles are designed with localized functional zones: the elastic core concentrates impact energy at the collision point to initiate microcracks, while the abrasive grains on the surface perform localized chemical etching, confining the removal action to the heat-affected layer without excessive penetration
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 method allows for efficient removal of the heat-affected layer without complex processes, improving fatigue strength by eliminating tensile stress and reducing surface roughness, thereby enhancing the durability and resistance to abrasion of the workpiece.
Implementation Method 1
irradiating a workpiece with a pulsed laser beam through a transparent liquid
Implementation Method 2
irradiating a workpiece with a pulsed laser beam through a transparent liquid
Implementation Method 3
causing particles to collide with a heat-affected layer
Implementation Method 4
abrasive grains provided on a surface of the core
Data Source
AI summary
A surface treatment method includes a step of irradiating a workpiece with a pulsed laser beam through a transparent liquid and a step of causing particles to collide with a heat-affected layer developed on a surface layer portion of the workpiece in the step of irradiating. The particles each has a core made of an elastic body and abrasive grains provided on a surface of the core.