Opposite-Surface Laser Cladding to Reduce Thermal Warpage
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Solution Overview
Problem
Conventional laser cladding methods face challenges with thermal warpage and non-uniform layer thickness due to asymmetric thermal stress and material shrinkage, especially when using high laser power outputs, leading to component doming and increased cycle times for processing opposite surfaces.
Innovation Solution
A laser cladding method that directs pulverulent filler material along a working trajectory on both opposite surfaces of a component using a laser beam, allowing simultaneous coating and reducing thermal warpage by maintaining symmetric thermal stress, and potentially halving the cycle time by eliminating the need for component repositioning and reducing the number of devices required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high laser power outputs are used for laser cladding, then coating speed and material deposition rate are improved, but thermal warpage and component doming increase due to asymmetric thermal stress
Solution Approach 1:
The patent applies asymmetry by using different laser power outputs on opposite surfaces of the component. During the first coating operation, a higher laser power output is used to achieve faster coating speed. During the second coating operation on the opposite surface, a lower laser power output is used to compensate for thermal stress and prevent excessive doming, while still maintaining productive coating deposition.
Solution Approach 2:
The patent changes the laser power output parameter between different coating operations. The first coating uses a first laser power output optimized for deposition rate, while the second coating uses a second laser power output optimized for thermal stress management. This parameter adjustment allows the system to balance productivity and manufacturing precision.
2Device complexity
If conventional single-sided coating methods are used, then equipment complexity is reduced, but production cycle time increases due to component repositioning
Solution Approach 1:
The patent merges two coating operations into a single production cycle by coating both opposite surfaces of the component in sequence using one laser cladding device. The component is coated on the first surface, then repositioned and coated on the opposite surface without removing the component from the device or requiring additional equipment, thus reducing overall cycle time.
Solution Approach 2:
The patent performs preliminary preparation of the component by applying a base coating on the first surface before repositioning for the second coating operation. This preliminary action ensures proper adhesion and prepares the surface for the subsequent coating, allowing efficient sequential processing.
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 method effectively reduces thermal warpage and doming, achieves symmetric coating layers, and significantly shortens the production cycle time while maintaining high thermal symmetry and quality, even with high laser power outputs.
Implementation Method 1
heating the filler material and the component by directing a respective laser beam along the respective working trajectory so that the filler material binds to the component as the filler material meets the respective surface
Implementation Method 2
melting a surface of a component by means of a laser beam and supplying the melt bath formed with a pulverulent filler material. The powder is then likewise melted in the melt bath
Implementation Method 3
The powder is then likewise melted in the melt bath, such that, after solidification of the molten powder material and the surface, a cohesively bonded, especially metallurgically bonded, material layer is formed
Data Source
AI summary
A laser cladding method includes directing a filler material in a pulverulent form along a respective working trajectory onto each respective surface of two mutually opposite surfaces of a component, and heating the filler material and the component by directing a respective laser beam along the respective working trajectory so that the filler material binds to the component as the filler material meets the respective surface, thereby producing coating layers on the two mutually opposite surfaces at least partly at a same time.