Ring-Shaped Laser Wire Deposition for Perpendicular Wire Feeding
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Solution Overview
Problem
Laser additive manufacturing of metals faces directional issues due to angled delivery of material wires, leading to misalignment and reduced accuracy in 2D and 3D applications.
Innovation Solution
A laser wire deposition head assembly that directs a laser beam into a donut or ring shape using a splitting mirror with reflective surfaces, allowing the material wire to be fed perpendicular to the base substrate, eliminating directional dependencies and enhancing alignment tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the material wire is delivered at an angle to the base substrate, then the wire can be fed into the laser, but directional issues arise and misalignment occurs between the wire and laser focus
Solution Approach 1:
The laser beam is segmented into multiple separate beams that are spatially distributed around the wire delivery path. This segmentation allows the wire to be fed perpendicular to the substrate without interfering with a single concentrated beam, eliminating the need for angled wire delivery while maintaining precise focal point alignment.
Solution Approach 2:
The invention transitions from a single-point laser focus to a multi-dimensional beam arrangement where multiple beams are distributed in space around the wire. This dimensional change allows the wire to pass through the center of the beam arrangement perpendicular to the substrate, resolving the conflict between wire delivery ease and alignment precision.
2Device complexity
If a single laser beam is used, then the setup is simple, but directional dependencies and misalignment issues occur in 2D and 3D applications
Solution Approach 1:
The single laser beam is divided into multiple segmented beams that are spatially distributed. This segmentation enables the system to accommodate wire delivery from multiple directions and positions, providing directional independence while maintaining a relatively simple overall laser configuration using beam splitting optics.
Solution Approach 2:
The multi-beam configuration serves multiple functions: it maintains laser focus precision, allows perpendicular wire delivery, provides directional independence for 2D and 3D applications, and creates a larger process window. This universal configuration replaces the need for complex angled delivery setups.
3Productivity
If the wire is fed at an angle, then material can be deposited, but the process window is small and misalignment is sensitive
Solution Approach 1:
By segmenting the laser beam into multiple spatially distributed beams, the system creates a larger effective process window. The wire can be fed perpendicular to the substrate through the center of the beam arrangement, providing generous alignment tolerance while maintaining full deposition capability across the build area.
4Ease of manufacture
If angled wire delivery is used, then the laser can process the wire, but build width accuracy is reduced and parts are farther from net shape
Solution Approach 1:
The invention changes the spatial arrangement from a single-beam configuration requiring angled wire delivery to a multi-dimensional beam distribution where wires are fed perpendicular to the substrate. This dimensional change enables precise build width control and produces parts closer to net shape while maintaining full processing capability.
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 solution provides an omni-directional deposition process with improved accuracy and a larger process window, resulting in material savings and closer adherence to the net shape in 3D printing applications.
Implementation Method 1
The splitting mirror includes a plurality of reflective surfaces distinct from one another to ultimately shape a donut or ring shaped beam at the focus plane. The laser beam is directed towards and reflected off of the plurality of reflective surfaces to split or separate the laser beam into a plurality of split beam segments
Implementation Method 2
A plurality of redirecting mirrors are arranged circumferentially about the axis in spaced relationship with one another and each in radially aligned relationship with a respective one of the plurality of split beam segments to redirect and shape each respective split beam segment back towards the axis and into a plurality of shaped beam segments
Implementation Method 3
A material wire is fed in between adjacent ones of the plurality of shaped beam segments, and then directed along the axis and through the center of the ring or donut shaped beam, leading to a melting of the material wire by the ring or donut shaped beam at the focus plane
Data Source
AI summary
An assembly and related method of wire laser deposition includes a splitting mirror presenting a plurality of reflective surfaces being distinct from one another. A laser beam is directed towards and reflected off the reflective surfaces and into a plurality of split beam segments traveling radially outwardly from the splitting mirror. A plurality of redirecting mirrors are each disposed in aligned relationship with a respective one of the split segments to redirect and shape each respective beam segment into a shaped beam segment extending towards a focus plane PF. The shaped beam segments extend in circumferentially spaced relationship to one another and are collectively reassembled into a ring shaped beam having a center. A material wire is fed between an adjacent pair of shaped beam segments and through the center of the ring shaped beam for disposing the material wire perpendicular to a base substrate for processing.