Opposing Injector Guide Nozzle for Uniform Laser Cladding
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Solution Overview
Problem
Existing laser cladding techniques often result in imperfections such as wavy functional layers, bonding defects, pores, cracks, and dissolution of hard material particles due to improper application of filler material, leading to reduced resilience and stability of the workpiece.
Innovation Solution
A jet nozzle design with opposing injector guides and a powder unit that allows for precise application of powdered filler material, utilizing multiple process zones with adjustable laser beam guidance and heat management to ensure smooth and stable functional layer deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional laser cladding techniques are used, then the functional layer can be applied to increase load-bearing capacity, but imperfections such as wavy layers, bonding defects, pores, and cracks occur in the internal material structure
Solution Approach 1:
The jet nozzle is divided into multiple independent injector guides (at least three injector guides) that can be individually adjusted. Each injector guide contains a powder injector that can be independently positioned and angled, allowing precise control over powder distribution across different zones of the workpiece surface, thereby eliminating wavy layers and bonding defects
Solution Approach 2:
The injector guides are designed with adjustable positioning mechanisms that allow dynamic adaptation of the nozzle configuration. The injector guides can be individually adjusted in position and angle to optimize powder delivery for different workpiece geometries and cladding requirements, preventing imperfections in the internal material structure
2Productivity
If high-speed laser cladding is used to increase productivity, then deposition speed is improved, but improper application of filler material leads to more frequent imperfections
Solution Approach 1:
The powder delivery system is segmented into multiple independent injector guides that can be individually optimized for high-speed operation. Each injector guide maintains precise powder delivery control even at high deposition speeds, ensuring proper filler material application while increasing productivity
Solution Approach 2:
The system allows independent adjustment of parameters for each injector guide including powder flow rate, injector angle, and position. These parameters can be dynamically changed to optimize both deposition speed and filler material application quality, preventing imperfections while maintaining high productivity
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
The jet nozzle reduces imperfections by ensuring uniform application of filler material, preventing bonding defects, pores, and cracks, thereby enhancing the quality and resilience of the functional layer and workpiece.
Implementation Method 1
a light channel (3) for conducting at least one laser beam (110) directed onto a workpiece (100)
Implementation Method 2
a powder unit (7) arranged radially outside the light channel (3) for conducting at least one jet of powder which is to be applied to the workpiece (100)
Data Source
AI summary
A jet nozzle is for laser cladding along a direction of advance. The jet nozzle includes a light channel for conducting at least one laser beam directed onto a workpiece; and a powder unit arranged radially outside the light channel for conducting at least one jet of powder which is to be applied to the workpiece with at least a first powder focus. The powder unit forms a powder section at a mouth of the jet nozzle in a circumferential direction around the light channel. The powder section includes a plurality of injector guides, into each of which a powder injector is configured to be inserted. A first injector guide is located substantially opposite a second injector guide in relation to the first powder focus.