Mold Cooling Passage Build-Up Welding Without Channel Damage
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Solution Overview
Problem
The existing method of manufacturing molds with cooling passages using high-output lasers for build-up welding is inefficient as it damages the channel members due to excessive heat input, making it difficult to produce molds quickly while preventing damage.
Innovation Solution
A method involving two lasers with different outputs and energy densities is used: a first pulsed laser for initial build-up welding to prevent damage and a second continuous wave laser for faster build-up welding, allowing for quicker mold production without damaging the channel members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high-output laser is used for build-up welding to reduce manufacturing time, then productivity is improved, but the channel member is damaged due to excessive heat input
Solution Approach 1:
The build-up welding process is divided into two distinct stages: first build-up welding using a first laser (lower output, lower energy density) to close the opening part without damaging the channel member, and second build-up welding using a second laser (higher output, higher energy density) to efficiently build up the mold body. This segmentation allows each laser to be optimized for its specific function, resolving the contradiction between speed and damage prevention.
Solution Approach 2:
The first build-up welding is performed as a preliminary action to close the opening part of the recessed groove and protect the channel member before the main build-up welding process. This preliminary protection layer prevents direct exposure of the channel member to the high-energy second laser, enabling fast manufacturing without damage.
2Reliability
If a low-output laser is used for build-up welding to prevent channel member damage, then reliability is improved, but manufacturing time increases
Solution Approach 1:
The welding process is segmented into two phases with different laser outputs. The first phase uses lower energy to protect the channel member, while the second phase uses higher energy for rapid material deposition. This eliminates the need to choose between speed and safety, as both are achieved in different stages.
Solution Approach 2:
The laser output and energy density parameters are changed between two welding passes. The first pass uses parameter settings suitable for precision work near the channel member, while the second pass uses parameters optimized for production speed. This parameter variation resolves the time-reliability trade-off.
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 manufacturing of molds with cooling passages in a short time while preventing channel member damage, ensuring efficient production and maintaining the integrity of the channel members.
Implementation Method 1
irradiating an opening part of the recessed groove with a first laser at a first output and a first energy density, the first laser being set in such a way that the channel member is prevented from being damaged, thereby performing a first build-up welding
Implementation Method 2
irradiating a region on a surface of the mold body including a region where the first build-up welding has been performed with a second laser at a second output that is higher than the first output and a second energy density that is lower than the first energy density, thereby performing a second build-up welding
Data Source
AI summary
A method of manufacturing a mold includes the processes of: arranging a channel member in a recessed groove formed on a surface of a mold body; irradiating an opening part of the recessed groove with a first laser, thereby performing a first build-up welding on a part in the vicinity of the opening part of the recessed groove; and irradiating a region on a surface of the mold body including a region where the first build-up welding has been performed with a second laser, thereby performing a second build-up welding on a region on the surface of the mold body including the region where the first build-up welding has been performed.