Segmented Jet Nozzle Layout for Stable Laser Deposition Welding
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Solution Overview
Problem
Laser deposition welding methods often result in imperfections such as bonding defects, pores, cracks, and dissolution of hard material particles in the functional layer due to inadequate heating and thermal stresses, which affect the load-bearing capacity of the workpiece.
Innovation Solution
A jet nozzle design with a light channel for laser beams, a powder unit for powdered filler material, and a process-gas unit surrounding the light channel to stabilize the process zones, allowing for precise control of laser beam guidance, filler material application, and heat management, thereby reducing imperfections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional laser deposition welding is used to apply a functional layer, then the load-bearing capacity of the workpiece is increased, but imperfections such as bonding defects, pores, cracks, and dissolution of hard material particles occur in the internal material structure
Solution Approach 1:
The jet nozzle is divided into distinct functional segments: a light channel for laser beam guidance, a powder unit for filler material application, and a process-gas unit for thermal management. This segmentation allows independent optimization of each function to prevent material structure imperfections while maintaining load-bearing capacity enhancement
Solution Approach 2:
The process gas acts as an intermediary between the laser beam and the workpiece surface. It stabilizes the heating process and protects the molten material from direct laser radiation, preventing bonding defects, pores, and cracks in the functional layer while still allowing the laser to increase load-bearing capacity
2Temperature
If the process gas directly contacts the workpiece surface, then thermal management is improved, but the functional layer quality deteriorates due to gas interference with material deposition
Solution Approach 1:
The process gas is directed to contact only the workpiece surface in specific regions, not the entire deposition zone. The jet nozzle design ensures gas flows along the light channel exterior and contacts the workpiece in a controlled manner, providing thermal management without interfering with functional layer material deposition and quality
Solution Approach 2:
The process gas unit is positioned radially outside the light channel, creating a spatial separation between the gas flow path and the direct laser-material interaction zone. This dimensional arrangement allows thermal management in one spatial dimension while preserving material deposition quality in another dimension
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
The jet nozzle enhances welding quality by minimizing bonding defects, pores, and cracks, and prevents the dissolution of hard material particles, ensuring reliable and precise laser deposition welding with improved load-bearing capacity.
Implementation Method 1
A jet nozzle for laser deposition welding in an advance direction is proposed
Implementation Method 2
EP 3 802 712 A2 describes a jet nozzle for laser beam welding with a shielding gas unit
Data Source
AI summary
A jet nozzle for laser deposition welding in an advance direction includes a light channel for guiding at least one laser beam to be directed at a workpiece, and a powder unit arranged radially outside the light channel for guiding at least one powder jet to be applied to the workpiece. The powder unit forms a powder portion in a peripheral direction around the light channel. The jet nozzle further includes a process-gas unit arranged radially outside the light channel for guiding a process gas. The process-gas unit forms a process-gas portion in the peripheral direction. The process-gas portion adjoins the powder portion at a nozzle mouth in the peripheral direction.