Multi-Laser Beam Gun Additive Manufacturing Thermal Control
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Solution Overview
Problem
Traditional additive manufacturing systems have limited control over heating and cooling cycles of melt pools, affecting microstructure development and workpiece composition characteristics, leading to poor properties.
Innovation Solution
An additive manufacturing system employing a multi-laser beam gun with a primary and secondary energy source, where the secondary energy beam is used to pre-heat or post-heat regions before melting, allowing for controlled solidification rates and microstructure development by adjusting the distance between focused energy hot spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single laser beam is used for melting powder bed, then the system structure is simple, but the control over heating and cooling cycles of melt pools is limited
Solution Approach 1:
The single laser beam is segmented into multiple independent laser beams (first laser beam and second laser beam) that can be independently controlled. The first laser beam creates the melt pool while the second laser beam controls heating and cooling cycles, allowing precise microstructure development without requiring a completely complex multi-component system.
Solution Approach 2:
The second laser beam performs preliminary heating action on the powder bed before the first laser beam creates the melt pool. This pre-heating control allows optimization of the heating rate and temperature distribution, leading to better microstructure development and reduced residual stresses.
2Ease of operation
If a single laser beam is used for melting powder bed, then the system operation is simple, but the microstructure development and workpiece composition characteristics are poor
Solution Approach 1:
The laser beam is segmented into multiple independently controllable beams, enabling separate control of melting process and thermal cycle management. This segmentation maintains operational simplicity while significantly improving microstructure development through coordinated multi-beam control.
Solution Approach 2:
Different laser beams operate with different parameters (power, speed, focal position, pulse duration) to independently control heating rate, melting rate, and cooling rate. This parameter optimization enables precise control over solidification rates and microstructure formation without complicating the operational interface.
3Manufacturing precision
If multiple laser beams are used to enhance control over heating and cooling cycles, then microstructure development is improved, but the device complexity increases
Solution Approach 1:
Multiple laser beams are merged into a single multi-beam gun assembly that delivers all beams through a shared optical path and focusing system. This merging approach enables precise microstructure control with minimal increase in device complexity, as the beams share common components rather than requiring separate delivery systems.
Solution Approach 2:
The multi-beam laser system provides multi-functionality within a single device: one beam performs melting while another performs thermal cycle control, and the same system can be adjusted for different material types and microstructure requirements. This universality reduces overall system complexity by consolidating multiple functions into one adaptable platform.
4Manufacturing precision
If multiple laser beams are used to control heating and cooling cycles, then workpiece properties are improved, but the energy consumption increases
Solution Approach 1:
The second laser beam performs preliminary heating to optimize the thermal state before melting, reducing the total energy required for the melting process. By pre-heating the powder bed to the optimal temperature, the first laser beam requires less energy to create and maintain the melt pool, overall reducing energy consumption while improving workpiece properties.
Solution Approach 2:
The system optimizes energy consumption by dynamically adjusting parameters of each laser beam based on real-time process requirements. The second beam uses lower power for thermal management while the first beam concentrates energy for melting, achieving efficient energy distribution that improves workpiece properties without excessive energy consumption.
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 enhances control over microstructure development and reduces internal stresses in the workpiece, improving composition characteristics and properties by optimizing heating and cooling cycles.
Implementation Method 1
a first energy beam focused on a first region of the layer to melt the first region into a melt pool
Implementation Method 2
a second energy beam focused on a second region of the substrate or melt pool to pre-heat or post-heat the second region
Data Source
Figure 1
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Figure 4~5
AI summary
An additive manufacturing system includes an energy gun having a plurality of energy source devices each emitting an energy beam. A primary beam melts a selected region of a substrate into a melt pool and at least one secondary beam heat-conditions the substrate proximate the melt pool to reduce workpiece internal stress and/or enhance micro-structure composition of the workpiece.