Laser Metal Deposition Nozzle Trajectory Control
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Solution Overview
Problem
The challenge in manufacturing or repairing turbomachine parts using Laser Metal Deposition is achieving consistent dimensional accuracy due to variations in powder flow rate, laser power, and temperature, leading to unstable deposits and surface irregularities like sawtooth patterns.
Innovation Solution
Adjusting the nozzle's trajectory over time by modifying the number of deposition steps and maintaining a consistent distance between the nozzle and substrate, while using an autofocus camera for precise distance measurements to ensure accurate layer deposition, allows for better control of the part's height and surface quality without altering process parameters like laser power or powder flow rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If process parameters (laser power, powder flow rate, reloading speed) are varied to adjust deposition height, then dimensional accuracy can be improved, but process stability deteriorates and surface quality worsens due to sawtooth patterns
Solution Approach 1:
The patent implements dynamic adjustment of the nozzle trajectory by modifying the predetermined number of deposition steps based on real-time distance measurements. Instead of varying process parameters like laser power or powder flow rate, the system dynamically changes the number of layers to be deposited, allowing adaptation to dimensional variations while maintaining stable process conditions and avoiding surface defects
Solution Approach 2:
The patent changes the control parameter from process parameters (laser power, powder flow rate) to geometric parameters (number of deposition steps, nozzle trajectory). By modifying the number of layers to be deposited rather than altering deposition conditions, the system achieves dimensional control while maintaining process stability and surface quality
2Manufacturing precision
If the number of deposition steps is increased to achieve target height, then dimensional accuracy improves, but manufacturing time increases
Solution Approach 1:
The patent implements a feedback mechanism where real-time distance measurements between the nozzle and substrate surface are used to adjust the predetermined number of deposition steps. The measurement unit continuously monitors the actual distance, and the control unit modifies the trajectory accordingly, ensuring accurate height control while optimizing the number of steps required rather than using a fixed excessive number of layers
Solution Approach 2:
The patent performs preliminary measurement of the initial distance between nozzle and substrate before beginning deposition. This preliminary action allows the system to calculate the optimal number of deposition steps needed to reach the target height, avoiding both insufficient deposition and unnecessary excessive layers that would waste time
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 stabilizes the deposition process, ensuring accurate dimensional characteristics and surface smoothness by dynamically adjusting the nozzle's path based on real-time measurements, thereby enhancing the precision and reliability of the manufacturing process.
Implementation Method 1
a laser beam (13) melts the powder (3)
Implementation Method 2
a nozzle (1) projects a metal powder (3) towards a substrate (5)... produce the part by successive deposits... of layers (11)
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
The invention relates to a method for producing a turbomachine part by means of a laser process. According to the invention, a part is made by means of a laser beam, with a nozzle (1) that sprays a metal powder towards a substrate (5). Initially, the trajectory of the nozzle is defined in a pre-determined manner, and then, during the production of the part (7), a theoretical reference distance D0 that has been previously recorded and a real distance which is then measured are compared, and the trajectory of the nozzle is modified on the basis of a deviation threshold between said distances.