Pulsed Laser Metal Powder Shaping for Narrow 3D Features
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Solution Overview
Problem
The existing three-dimensional shaping techniques, such as the PBF method, face limitations in miniaturization due to the balling defect, which results in a minimum shaping width of over 150 μm, making it difficult to achieve continuous shaping bodies with narrower dimensions.
Innovation Solution
A three-dimensional shaping method using a pulsed laser with a frequency of 5 to 200 kHz, pulse width of 5 to 200 μs, and peak output of 10 to 500 W, along with an overlap rate of 50 to 99.9% for the laser light irradiation, to form layers of metal powder, allowing for a narrower shaping width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the laser output is reduced and scanning speed is increased to narrow the shaping width, then the molten region becomes narrower, but balling defects occur and continuity of the shaping body is lost
Solution Approach 1:
The patent applies periodic pulsed laser irradiation instead of continuous laser irradiation. By controlling the pulse frequency (5-200 kHz), pulse width (5-200 μs), and overlap rate (50-99.9%), the method enables narrow shaping width while preventing balling defects and maintaining continuity of the shaping body through controlled periodic melting and solidification cycles
2Length of moving object
If the amount of heat is reduced to narrow the shaping width, then the molten region becomes smaller, but the molten pool is not formed and particles coagulate into larger masses
Solution Approach 1:
The pulsed laser irradiation with controlled frequency and pulse width creates periodic heating cycles that form stable molten pools. The pulse timing and duration are optimized to ensure complete melting of particles and formation of uniform molten pools, preventing coagulation while achieving narrow shaping width
Solution Approach 2:
The patent optimizes multiple laser parameters simultaneously (frequency: 5-200 kHz, pulse width: 5-200 μs, peak output: 10-500 W, overlap rate: 50-99.9%) to achieve the desired balancing act between narrow shaping width and uniform composition, demonstrating parameter changes as a comprehensive solution
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 the shaping of bodies with a narrower shaping width, enhancing the continuity and accuracy of the shaping process, overcoming the limitations of the balling defect and achieving miniaturization of beam and column parts in complex structures.
Implementation Method 1
a laser light irradiation process to irradiate the layer of metal powder formed in the layer forming process with a laser light
Implementation Method 2
it is necessary that the particle is melted and a molten pool in the structure directly below the particle is formed
Implementation Method 3
particles around itself are captured by the surface tension to become a larger mass
Data Source
AI summary
The three-dimensional shaping device (100) is provided with a layer forming device (10) to form a layer of metal powder (90) on a shaping object, and a laser light irradiation device (20) to irradiate the layer of metal powder (90) formed by the layer forming device (10) with a laser light (25). The laser light (25) to be used in the three-dimensional shaping device (100) has a pulsed output waveform with a frequency of 5 to 200 kHz, a pulse width of 5 to 200 μs and a peak output of 10 to 500 W. Further, an overlap rate, which is a rate at which irradiation spots on the layer of metal powder (90) by two successive pulses of the laser light (25) overlap with each other, is 50 to 99.9%. Hereby, it is possible to provide a three-dimensional shaping method and a three-dimensional shaping device which can shape a shaping body having a narrower shaping width.