Powder Nozzle Misalignment Detection via Test Structure
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Solution Overview
Problem
In laser material processing with powder, achieving accurate alignment between the powder feed nozzle and the laser beam is challenging, particularly when forming multiple layers, leading to inconsistent and reproducible layer quality.
Innovation Solution
A method involving the formation and analysis of a test structure on the workpiece using deposition laser welding allows for the detection and correction of misalignment between the powder feed nozzle and the laser beam by measuring height and wall thickness variations, enabling precise adjustment of the nozzle relative to the laser beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If process monitoring and control techniques are implemented to adjust laser power and feed rate, then layer quality can be improved, but the alignment between powder feed nozzle and laser beam remains inconsistent leading to reproducible quality issues
Solution Approach 1:
The patent applies preliminary action by forming a test structure before actual production layers to detect and correct nozzle misalignment. The test structure is deposited using the same powder feed nozzle and laser beam combination, allowing alignment issues to be identified and adjusted before they affect production quality. This preliminary detection step ensures that subsequent layers are deposited with proper alignment, making the process self-correcting.
Solution Approach 2:
The system performs self-service by using its own deposition capabilities to create a test structure that reveals alignment problems. The same powder feed nozzle and laser beam that will be used for production are used to deposit the test structure, allowing the system to self-diagnose alignment issues without external intervention. The test structure's geometric properties serve as an automatic alignment indicator.
2Productivity
If deposition laser welding is performed with constant parameters to form multiple layers, then productivity is maintained, but misalignment between powder focus and laser beam causes varying layer heights and quality inconsistencies
Solution Approach 1:
The test structure is deposited beforehand using constant deposition parameters to reveal alignment issues before production begins. By forming this preliminary test structure with the same parameters intended for production, any alignment problems manifest in the test structure's geometry, allowing correction before actual production layers are deposited, thus ensuring both productivity and precision in subsequent operations.
Solution Approach 2:
The system implements feedback by measuring the geometric properties (heights, wall thicknesses) of the test structure and using this information to determine the direction and amount of misalignment. This feedback loop allows the system to automatically adjust the relative positioning of the powder feed nozzle and laser beam, correcting alignment issues while maintaining constant deposition parameters for high productivity.
3Ease of operation
If the powder feed nozzle and laser beam are manually aligned, then initial setup is simple, but alignment drift occurs during operation requiring time-consuming recalibration
Solution Approach 1:
The system performs self-service alignment by automatically detecting misalignment through test structure measurement and calculating the required correction. This eliminates the need for manual alignment adjustments and removes alignment drift issues entirely, as the system self-corrects based on actual deposition characteristics rather than relying on manual positioning that may drift during operation.
Solution Approach 2:
The test structure serves as a preliminary alignment reference that is formed before production begins. By measuring this test structure's geometric properties, the system determines the actual alignment state and calculates corrective positioning. This preliminary measurement and correction step ensures stable alignment throughout operation without requiring time-consuming manual recalibration.
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 enables more accurate and automated alignment of the powder feed nozzle and laser beam, improving the uniformity and reproducibility of layer characteristics, and allows for the identification of quality deviations in the powder and beam parameters.
Implementation Method 1
metal powder is applied onto a substrate through introduction of laser beam energy
Implementation Method 2
laser metal deposition (LMD), metal powder is applied onto a substrate through introduction of laser beam energy
Data Source
AI summary
This invention relates to a method for determining misalignment of a powder feed nozzle and a laser beam. The method includes forming a test structure on a workpiece in at least two different directions by deposition laser welding with powder at substantially constant deposition parameters without relative rotation between a powder feed nozzle and a laser beam, measuring heights and/or wall thicknesses of the test structure along the test structure, and determining a direction and/or an amount of misalignment of the powder feed nozzle relative to the laser beam based on the measured heights and/or wall thicknesses.