LMD Projection Build-Up for Constant-Width Columnar Features
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Solution Overview
Problem
Conventional laser metal deposition (LMD) methods for forming projections result in a trapezoidal or triangular sectional shape, leading to wasteful projections when attempting to create columnar bodies, as the fusion zone flows down at the edges, limiting the formation of projections with a constant width.
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 formed along the edges to maintain edge alignment, allowing for the creation of projections with a substantially constant width through controlled laser deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional LMD method is used to form projections, then the process is simple, but the projection width varies and cannot maintain constant width
Solution Approach 1:
The deposition process is segmented into multiple sequential stages: forming a first bank, depositing a first layer, forming a second bank, and depositing a second layer. Each stage serves a specific function in controlling the projection geometry, with the banks acting as structural frameworks that define the projection boundaries and prevent width variation.
Solution Approach 2:
The first and second banks are formed in advance before the corresponding layers are deposited. These banks serve as preliminary structural elements that pre-define the projection boundaries and provide a framework that guides subsequent material deposition, ensuring constant width from the outset rather than attempting to correct width variations afterward.
2Manufacturing precision
If banks and layers are formed in sequence with banks surrounding previous layers, then fusion zone flow-down is suppressed and edge alignment is maintained, but material consumption increases
Solution Approach 1:
Different regions of the deposition structure serve different functions: the banks provide structural definition and edge control, while the layers provide material buildup and height control. This local differentiation allows each component to optimize its specific function, with banks minimizing flow-down at critical edges and layers efficiently building the projection body.
Solution Approach 2:
The banks are formed in advance to establish the projection boundaries before the layers are deposited. This preliminary action creates a structural framework that prevents material flow-down during subsequent deposition, ensuring edge alignment is maintained throughout the process rather than requiring excessive material to compensate for flow-down.
3Ease of manufacture
If projection size is increased to accommodate machine work, then columnar body formation is possible, but material waste increases
Solution Approach 1:
The bank structure acts as a confining framework that directs and contains the deposited material within precise boundaries. Similar to how hydraulic systems use confined channels to direct fluid flow, the banks create a confined deposition zone that prevents material spread beyond the intended projection width, enabling precise columnar body formation without excessive material waste.
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 enables the formation of projections with a consistent width, such as columnar or flange shapes, by suppressing fusion zone flow-down, ensuring stable heat input and preventing defects like porosity, thereby enhancing the internal quality and strength of the final product.
Implementation Method 1
a laser beam 91 while spraying metal powder 92
Implementation Method 2
fuse the surface 11
Implementation Method 3
spraying metal powder 92 from a nozzle 9 onto the surface 11
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
A projection forming method is a method of 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 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.