Rotatable Nozzle Frame for Uniform Laser Powder Fusion
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Solution Overview
Problem
Current additive manufacturing by laser fusion of metal powders faces issues with non-uniformity, porosity, and microfractures due to uncontrolled temperature gradients during pre-heating, fusion, and post-heating phases, limiting the quality and structural integrity of the produced objects.
Innovation Solution
A laser operating machine with a mobile movement structure and rotatable nozzle frame allows for precise control of the laser beam's energy profile and orientation, enabling independent adjustments of the nozzles' inclination and the laser spot's position to minimize interference and optimize temperature gradients, thereby improving the deposition process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed nozzle frame is used for laser fusion, then the structure is simple and easy to manufacture, but the freedom to control energy profiles and orient the laser beam is limited
Solution Approach 1:
The patent applies the dynamics principle by making the nozzle frame rotatable about a vertical axis, transforming it from a static to a dynamic structure. This rotation capability enables the laser beam to be oriented in different directions and positions, providing freedom to control energy profiles for pre-heating, fusion, and post-heating zones without being constrained by a fixed frame geometry.
2Adaptability or versatility
If the laser beam is constrained by the nozzle frame structure, then the device complexity is reduced, but the ability to apply controlled energy profiles to pre-heating and post-heating zones is limited
Solution Approach 1:
The rotatable nozzle frame enables dynamic adjustment of laser beam orientation, allowing the system to apply controlled energy profiles to different zones (pre-heating, fusion, post-heating) by rotating the frame to appropriate angles, thus achieving adaptability without excessive complexity.
3Manufacturing precision
If the nozzles are fixed in position, then the device is easier to manufacture, but the deposition quality and uniformity are affected due to changing relative positions along the path
Solution Approach 1:
The rotatable nozzle frame maintains optimal relative positioning between the nozzles and the deposition path by rotating to appropriate angles during movement, ensuring consistent deposition quality and uniformity despite the dynamic nature of the process.
4Object-affected harmful factors
If the laser beam path is fixed relative to the nozzles, then the system is simpler to control, but the risk of interception by nozzles or powder jets increases
Solution Approach 1:
The rotatable nozzle frame dynamically adjusts the relative position and orientation of nozzles with respect to the laser beam path, allowing the system to rotate nozzles out of the laser beam's path when necessary, thereby eliminating interception risks while maintaining control through coordinated rotation and movement.
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 enhances the uniformity and quality of the additive manufacturing process by allowing for flexible control of energy profiles and precise positioning of the laser beam, reducing the risk of microfractures and improving the structural integrity of the produced objects.
Implementation Method 1
an optical laser assembly for conveying a laser beam to form a laser spot focused on said working substrate in order to carry out thermal treatment on said powders
Implementation Method 2
the additive-manufacturing process, by bringing the material in the melt pool to fusion, determines a phase change (fusion) in the state of the material. Generally, the molten phase has a greater volume than the solid phase so that in the solidification step there is a contraction of the material
Data Source
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AI summary
A laser operating machine for additive manufacture of objects, via a process of laser thermal treatment of metal powders, in particular via fusion, comprising a movement structure (11), which is mobile in a working space (100) that comprises a working surface (110), said machine operating according to a first cartesian system of axes of movement (X, Y, Z) and being configured for supporting a moving element (12) comprising one or more nozzles (34) for emitting jets of powder to be treated thermally onto a working substrate (100, 110), and an optical laser assembly (20) for conveying a laser beam (L) to form a laser spot (S) focused on said working substrate (100, 110) in order to carry out thermal treatment of said powders. According to the invention, said moving element (12) comprises: an upper portion fixedly associated to said movement structure, said optical laser assembly (20) being set in said upper portion; and a lower portion, rotatable about an axis (ζ) parallel to a vertical axis (Z) of said first system of cartesian axes (X, Y, Z), set in which is a tool- carrier frame (30), arranged on which are said one or more nozzles (34) for emitting jets of powder, said optical laser assembly (20) being set in the moving element (12) so as to send the laser beam (L) onto the working surface (110), passing within a perimeter defined by said plurality of nozzles (34) for emitting jets of powder.