LMD Projection Forming with Banks for Constant-Width Builds
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Solution Overview
Problem
Conventional projection forming methods using laser metal deposition (LMD) result in projections with non-constant widths, leading to wastefulness when attempting to form columnar bodies, as the fusion zone flow-down at edges restricts the formation of projections with uniform dimensions.
Innovation Solution
A method involving the formation of a first bank surrounding the projection region, followed by a first layer that covers the bank, with subsequent height raising layers and banks to suppress fusion zone flow-down, allowing for the creation of projections with a substantially constant width through laminated layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the third beads are formed at positions slightly inward of the positions right above the first beads to prevent flow-down of fusion zone, then the flow-down is suppressed, but the projection width becomes non-constant (trapezoidal or triangular shape)
Solution Approach 1:
The method forms banks (first bank, second bank) in advance before depositing the height-raising layers. These banks act as preliminary structures that confine the molten metal during subsequent deposition, preventing flow-down while allowing the projection edges to maintain constant width. The banks are formed at positions that would otherwise be problematic, proactively preventing the flow-down issue before it occurs during height-raising layer deposition.
Solution Approach 2:
The banks serve as intermediary structures between the projection base and the height-raising layers. These intermediate banks confine the molten metal and guide the deposition process, enabling the formation of projections with constant width by mediating the interaction between the laser beam, filler material, and substrate.
2Ease of manufacture
If the projection is made relatively large to accommodate machine work for obtaining columnar body, then machine work can be performed, but material wastage increases
Solution Approach 1:
The method uses laser metal deposition technology, which involves controlled material deposition through a laser-induced melting process. The precise control of material addition allows for forming projections with exact dimensions, minimizing the need for subsequent material removal and reducing waste.
Solution Approach 2:
The method changes the deposition parameters (laser power, deposition rate, bank geometry) to directly form projections with constant width suitable for machine work. By controlling these parameters, the projection can be formed with precise dimensions that minimize material wastage during subsequent machining operations.
3Productivity
If conventional LMD method is used to form projection, then the process is simple, but the projection has non-constant width leading to inefficiency
Solution Approach 1:
The deposition process is segmented into distinct stages: forming the base layer, forming banks at specific positions, and then depositing height-raising layers. This segmentation allows for precise control of material deposition and enables the formation of projections with constant width, improving material utilization efficiency.
Solution Approach 2:
The method introduces a new dimensional element by forming banks that extend beyond the projection edges in the radial direction. This additional dimensional structure (the banks) provides confinement for the molten metal, enabling constant width projections that improve material efficiency.
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
Enables the formation of projections with a consistent width, facilitating the creation of columnar or flange-shaped projections with improved structural integrity and reduced material wastage, while maintaining stable heat input and surface quality.
Implementation Method 1
forming a first bank by laser metal deposition (LMD) such that the first bank surrounds a projection forming region on the surface of a work
Implementation Method 2
forming a first layer on the projection forming region by the LMD such that the first layer covers the first bank
Data Source
AI summary
A projection forming method forming a projection on the surface of a work and includes: forming a first bank by LMD such that the first bank surrounds a projection forming region on the surface of the work; forming a first layer on the projection forming region by the LMD such that the first layer covers the first bank; laminating at least one first height raising layer on the first layer by the LMD; forming a second bank by the LMD along a peripheral edge of the at least one first height raising layer; forming an intermediate base layer on the at least one first height raising layer by the LMD such that the intermediate base layer covers the second bank; and laminating at least one second height raising layer on the intermediate base layer by the LMD.