Laser-Induced Plasma Channel Heating for Dense 3D Metal Printing
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Solution Overview
Problem
Conventional selective laser sintering and melting processes in 3-D metal printing face inefficiencies due to reduced strength, high residual stresses, and porosity issues, primarily caused by incomplete sintering and localized heat application, leading to reduced mechanical properties and increased manufacturing time.
Innovation Solution
The method involves creating a laser-induced plasma channel and applying electric pulses through it to enhance the sintering and melting of metal powders, combining laser energy with electrical energy to improve consolidation and reduce deformation resistance, thereby increasing heating efficiency and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional selective laser sintering or melting is used, then metal powder can be consolidated into 3D objects, but the process suffers from incomplete sintering, high residual stresses, and porosity issues that reduce mechanical properties
Solution Approach 1:
The patent combines laser irradiation with electrical pulse delivery through a plasma channel to simultaneously provide thermal energy and electrical energy for sintering/melting metal powder. This dual-energy approach ensures more complete consolidation of powder particles, reducing porosity and improving mechanical properties while minimizing residual stresses through more uniform heating.
Solution Approach 2:
The patent introduces electrical pulses as an additional energy parameter to the conventional laser-based process. By applying high-voltage electrical pulses through the laser-induced plasma channel, the process transforms the single-energy-mode laser sintering into a dual-energy-mode process, fundamentally changing the energy delivery parameters to achieve better consolidation and reduced defects.
2Productivity
If laser beam is used for sintering or melting metal powder, then 3D objects can be fabricated, but the process is time-consuming and has reduced heating efficiency
Solution Approach 1:
The patent merges laser irradiation with electrical pulse delivery to provide dual energy input for rapid heating and sintering/melting of metal powder. The laser creates the plasma channel that guides electrical pulses, and both energy sources work synergistically to heat the powder more efficiently and rapidly than laser alone, thereby reducing manufacturing time while improving energy utilization.
Solution Approach 2:
The patent employs periodic electrical pulses delivered through the plasma channel during laser irradiation. This pulsed electrical energy delivery, combined with continuous or pulsed laser irradiation, creates a highly efficient periodic heating action that rapidly raises temperature to sintering/melting points, significantly reducing processing time compared to conventional continuous laser heating.
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 results in improved mechanical properties, reduced deformation resistance, increased efficiency, and enhanced reliability of printed metal parts by applying approximately four times more heat than conventional methods, addressing inefficiencies and porosity issues.
Implementation Method 1
irradiating a portion of powder in a powder bed, wherein the irradiation creates an ion channel extending to the powder
Implementation Method 2
the irradiation creates an ion channel extending to the powder
Implementation Method 3
applying electrical energy to the ion channel, wherein the electrical energy is transmitted through the ion channel to the powder in the powder bed
Implementation Method 4
energy from the irradiation and the electrical energy each contribute to melting or sintering the portion of the powder in the powder bed
Implementation Method 5
sintering or melting the powder by the laser
Implementation Method 6
melting or sintering the portion of the powder in the powder bed
Data Source
AI summary
A method of fabricating an object by additive manufacturing is provided. The method includes irradiating a portion of powder in a powder bed, the irradiation creating an ion channel extending to the powder. The method also includes applying electrical energy to the ion channel, wherein the electrical energy is transmitted through the ion channel to the powder in the powder bed, and energy from the irradiation and the electrical energy each contribute to melting or sintering the portion of the powder in the powder bed.