Plasma-Treated Additive Manufacturing Powder for Laser Absorption
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Solution Overview
Problem
Directed energy additive manufacturing is costly due to high feed material and energy consumption, particularly in powder bed and powder feed processes, where powder particles require significant energy to fuse and process efficiently.
Innovation Solution
Treating additive manufacturing powder particles with plasma radiation to form functional groups on their surfaces, enhancing their ability to absorb laser energy, thereby reducing the energy required for fusion and processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If powder particles are used in directed energy additive manufacturing, then the manufacturing process can be performed, but high energy consumption occurs
Solution Approach 1:
The patent applies parameter changes by modifying the surface properties of powder particles through plasma treatment. This treatment alters the surface energy, composition, and morphology of the particles, enabling them to absorb laser energy more efficiently. The plasma process changes parameters such as surface roughness, chemical composition, and wettability, which directly impact energy absorption characteristics and reduce the overall energy consumption during additive manufacturing
Solution Approach 2:
The patent employs composite materials by creating a hybrid surface structure on the powder particles. The plasma treatment introduces composite surface layers with different thermal and optical properties than the base material. This composite surface structure enhances laser energy absorption while maintaining the bulk material properties needed for proper melting and fusion during the additive manufacturing process
2Use of energy by moving object
If conventional powder particles are used, then material costs are high, but energy absorption capability is insufficient
Solution Approach 1:
The patent applies preliminary action by performing plasma treatment on the powder particles before they are used in the additive manufacturing process. This pre-treatment modifies the surface characteristics of the particles in advance, ensuring they have optimized energy absorption properties before encountering the laser beam. The plasma treatment is performed during material handling or storage, preparing the particles for efficient processing without requiring changes to the manufacturing equipment or process parameters
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 increased energy absorption of the treated powder particles decreases the energy consumption and processing time, leading to lower operational costs and improved efficiency in directed energy additive manufacturing.
Implementation Method 1
treating additive manufacturing powder particles with plasma radiation
Implementation Method 2
increases laser energy absorption of the additive manufacturing powder particles
Implementation Method 3
exposing the additive manufacturing powder particles to laser energy of an additive manufacturing process
Implementation Method 4
having molecular bonds that vibrate in response to irradiation by laser energy
Data Source
AI summary
An additive manufacturing powder particle including a surface and at least one functional group formed on the surface, wherein the at least one functional group increases laser energy absorption of the additive manufacturing powder particle. The additive manufacturing particle is treated with plasma radiation to form hydroxyl functional groups on a surface of the additive manufacturing powder particle, where the hydroxyl functional groups have a molecular vibrational frequency corresponding to a laser wavenumber range of laser energy of an additive manufacturing process, and where the plasma radiation treating the additive manufacturing powder particles depends on the laser energy of the additive manufacturing process. Treating the additive manufacturing powder particle with the plasma radiation increases laser energy absorption of the additive manufacturing powder particle when the additive manufacturing particle is exposed to the laser energy, produced by a carbon dioxide laser, of the additive manufacturing process.