Powder Bed Spatter Collection With Translating Gas Collection Zone
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Solution Overview
Problem
In additive manufacturing processes like direct metal laser melting, weld spatter and smoke contaminants often form metallurgical defects in the object due to the limited gas supply velocity and pressure, which fail to effectively remove these contaminants from the powder bed.
Innovation Solution
An additive manufacturing system with a spatter collection device that includes a diffuser and collector, translating relative to the powder bed in a coordinated motion with the laser emitters, providing a concentrated and precise stream of inert gas across a collection zone to efficiently remove contaminants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If gas supply velocity and pressure are increased to remove weld spatter and smoke, then contaminant removal effectiveness is improved, but the powder bed becomes disturbed
Solution Approach 1:
The gas flow system is segmented into multiple zones: a first gas flow path for contaminant removal and a second gas flow path for powder bed stabilization. This segmentation allows independent control of gas velocity and pressure in different regions, enabling effective spatter removal while maintaining powder bed stability.
Solution Approach 2:
Different gas flow characteristics are applied to different locations: high-velocity gas flow is directed at the melt pool area for spatter removal, while low-velocity gas flow is applied to the powder bed surface to maintain stability. This local differentiation resolves the contradiction between contaminant removal and powder bed stability.
2Device complexity
If a gas collection plenum is positioned on one side of the powder bed to collect contaminants, then contaminant collection is simplified, but the collection effectiveness is reduced due to limited gas supply velocity
Solution Approach 1:
The gas flow system transitions from a two-dimensional surface flow to a three-dimensional volumetric flow by introducing a vertical gas flow component. Gas is supplied from above the powder bed surface, creating a vertical flow path that enhances contaminant removal effectiveness while maintaining system simplicity.
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 reduces the likelihood of manufacturing defects by effectively removing weld spatter and smoke particles, allowing for larger powder bed areas and maintaining the integrity of the powder bed during the build operation.
Implementation Method 1
a diffuser configured to discharge a stream of gas across the powder bed
Implementation Method 2
an array of laser emitters configured to melt at least a portion of the powder bed
Implementation Method 3
a collector configured to receive the stream of gas and contaminants entrained in the stream of gas
Data Source
AI summary
An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.