Plasma Nozzle Deposition for Small-Scale Surface Features
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Solution Overview
Problem
Additive manufacturing techniques face challenges in creating complex surface features on small scales, requiring complex material formulations and multi-step post-processing, and are difficult to perform on intricate designs such as gas turbine components, magnetic systems, and optical devices.
Innovation Solution
A nozzle system with an induction coil around a plasma gas tube generates a controlled plasma flame for heating and shaping the plasma gas, allowing precise deposition of precursor materials through a sheath gas, which chemically modifies or reacts with the source material to produce the desired feature without direct contact, enabling one-step deposition and precise control on small scales.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing techniques are used to create surface features, then material can be deposited on surfaces, but complex material formulations and multi-step post-processing are required to obtain desired properties
Solution Approach 1:
The patent changes the physical and chemical parameters of the deposition process by using plasma state material and controlled plasma flames with specific temperatures and compositions. This allows direct deposition of materials with desired properties without complex formulations or post-processing, resolving the contradiction between manufacturing precision and device complexity
Solution Approach 2:
The patent employs composite plasma flames consisting of multiple gases (e.g., acetylene, hydrogen, oxygen, nitrogen) in specific ratios to achieve desired material properties directly during deposition. This eliminates the need for complex material formulations and multi-step post-processing while maintaining precise control over surface feature properties
2Manufacturing precision
If conventional additive manufacturing techniques are used, then material deposition can be performed, but the process is difficult to perform on a small scale
Solution Approach 1:
The patent applies local quality by using a focused plasma flame that can be precisely positioned and controlled at small scales. The plasma jet delivers energy and material locally to the deposition site, enabling precise manufacturing of small features while maintaining high deposition precision
Solution Approach 2:
The patent replaces conventional mechanical deposition systems with a plasma-based system. The plasma flame provides both heating and material delivery in a unified field-based approach, enabling precise control at small scales where mechanical systems become difficult to operate
3Manufacturing precision
If plasma flame is used for heating and shaping, then precise control is achieved, but contamination may occur if plasma contacts the component
Solution Approach 1:
The patent introduces a carrier gas or protective atmosphere as an intermediary between the plasma flame and the component surface. This mediator allows the plasma to perform heating and shaping functions while preventing direct contact that would cause contamination, thus maintaining both precise control and component purity
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 method allows for precise, contamination-free deposition of materials with desired properties on small scales, eliminating the need for post-processing and enabling the creation of complex features like those required for gas turbine engines, magnetic systems, and optical devices with improved material bonding and reduced defects.
Implementation Method 1
An induction coil 32 is arranged around the exterior of the plasma gas tube 31 and heats the plasma gas 29 to form the plasma flame 28
Implementation Method 2
The source material 38 is fed directly into the plasma flame 28 axially, the source material 38 is subjected to more uniform heating
Implementation Method 3
A plasma flame 28 is formed from a plasma gas 29... The source material 38 passes through the plasma flame 28 and is deposited onto the component 20
Data Source
Figure 1~3
AI summary
A nozzle (26) for additive manufacturing includes a plasma gas tube (31) operable to provide plasma gas (29) to a plasma flame (28), and a source material tube (36) arranged concentrically inside the plasma gas tube (31) such that source material (38) passes through the plasma flame (28). An apparatus and method for additive manufacturing are also disclosed.