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 the solidification period and suppressing hot cracking by releasing weld heat, and subsequent brazing is used to achieve self-healing.
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 base material is pre-cooled to a temperature of -100°C to -150°C before the laser metal deposition process begins. This preliminary cooling action reduces the solidification period during welding and suppresses hot cracking by releasing weld heat, thereby preventing structural integrity issues before they occur during the additive manufacturing or repair process.
Solution Approach 2:
The temperature parameter of the base material is changed from ambient temperature to a deep cooled state (-100°C to -150°C). This parameter change fundamentally alters the thermal conditions during laser metal deposition, reducing the solidification period and suppressing hot cracking while maintaining the ability to build additive structures.
2Strength
If high strength superalloys are used to achieve optimized mechanical properties, then strength and durability are improved, but susceptibility to hot cracking during welding increases
Solution Approach 1:
The base material is pre-cooled to -100°C to -150°C to create a thermal condition that opposes the harmful effect of hot cracking. This preliminary anti-action reduces the solidification period during welding and suppresses hot cracking by releasing weld heat, allowing high strength superalloys to be processed without suffering from their inherent cracking susceptibility.
Solution Approach 2:
The base material undergoes a phase transition from ambient temperature to a deep cooled state (-100°C to -150°C) using cooling media such as liquid nitrogen or liquid argon. This phase transition in temperature state fundamentally changes the thermal behavior during laser metal deposition, reducing solidification period and suppressing hot cracking in high strength superalloys.
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 method effectively suppresses hot cracking and ensures the structural integrity of the components by maintaining a controlled cooling temperature range during the welding process, allowing for the formation of high-quality superalloy components with reduced defects.
Implementation Method 1
cooling 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
cooling/freezing effect of the base material during laser processing
Implementation Method 3
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
Data Source
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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 5 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 10 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.