Laser Metal Deposition Cooling for Crack-Free Gamma Prime Superalloys
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Solution Overview
Problem
Superalloys used in additive manufacturing and repair via laser metal deposition are prone to hot cracking due to their high strength and low ductility, which compromises the structural integrity of the components.
Innovation Solution
A deep cooling effect is applied during the laser metal deposition process using a cooling medium like liquid nitrogen or argon to maintain a temperature range of −100° C. to −150° C., reducing solidification periods and suppressing hot cracking, combined with subsequent brazing to enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser metal deposition is used to build additively manufactured parts or repair superalloy components, then manufacturing capability and component repair are improved, but hot cracking occurs during the process compromising structural integrity
Solution Approach 1:
The patent applies deep cooling to change the temperature parameter of the base material from ambient temperature to cryogenic temperatures (−100° C. to −150° C.). This parameter change fundamentally alters the thermal conditions during LMD, reducing the solidification period from seconds to milliseconds, which suppresses hot cracking and improves structural integrity while maintaining additive manufacturing capability
Solution Approach 2:
The patent applies cooling to the base material before the laser metal deposition process begins. This preliminary anti-action counteracts the harmful thermal effects that would otherwise cause hot cracking during welding, preventing the problem before it occurs while allowing the LMD process to proceed
2Device complexity
If conventional LMD process is used without cooling, then processing is simpler, but solidification periods are long causing hot cracking
Solution Approach 1:
By introducing cryogenic cooling to change the base material temperature parameter, the patent reduces solidification period from seconds to milliseconds. This parameter change achieves superior crack suppression and manufacturing precision, with the cooling system integrated into the LMD 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
The deep cooling system effectively reduces or eliminates hot cracking during welding and subsequent heat treatment, ensuring the structural integrity of the components by shortening solidification periods and allowing for the release of weld heat, thereby improving the manufacturing and repair processes of superalloys.
Implementation Method 1
The means for cooling the base material may be configured to cool the base material, e.g., via a cooling medium, to a desired temperature with a cooling temperature range resulting in, e.g., a cooling/freezing effect of the base material during laser processing
Implementation Method 2
a cooling temperature range resulting in, e.g., a cooling/freezing effect of the base material during laser processing
Implementation Method 3
The LMD system may include a laser energy source operably configured to direct laser energy towards the base material to form a melt pool thereon
Implementation Method 4
The laser energy processes the additive materials deposited into the melt pool (e.g., on the base material) for forming layers of the additive materials upon solidification
Implementation Method 5
forming layers of the additive materials upon solidification
Data Source
AI summary
Systems (100) and methods (1000) for additively manufacturing or repairing a component from a base material (10). The system may include a laser metal deposition (LMD) system (200) operably connected to a means for cooling (300) the base material during laser processing of additive materials deposited in a melt pool on the base material. The LMD system includes a laser energy source (202) configured to direct laser energy towards the base material to form the melt pool thereon and to processes the deposited additive materials to form layers on the base material upon solidification. The means for cooling may be configured to cool the base material to within a cooling temperature range during the LMD process, which results in, e.g., a cooling/freezing effect. This cooling effect shortens the solidification period during laser processing and allows for weld heat to be released from the base material.