Selective Laser Brazing for Dense Additive Manufacturing
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Solution Overview
Problem
Selective Laser Sintering and Selective Laser Melting techniques face challenges in achieving full densification and uniform strength in components due to voids and directional crystal microstructure orientation, respectively.
Innovation Solution
Selective Laser Brazing method using parent core particles and braze particles, where the energy source is set above the melting point of braze particles but below that of the parent core particles, allowing the braze particles to melt and distribute by capillary action to fuse the parent core particles without melting them, resulting in a fully dense and uniformly strong component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If Selective Laser Sintering is used to manufacture components, then material bonding is achieved through diffusion, but full densification cannot be achieved and voids remain between particles
Solution Approach 1:
The patent applies parameter changes by adjusting the laser power and exposure time to achieve selective melting of braze particles at specific temperature ranges. This allows the braze material to flow and fill voids between parent particles, achieving full densification while maintaining component strength.
Solution Approach 2:
The patent utilizes phase transitions by heating the braze particles to their melting point while keeping parent particles solid. The braze material transitions from solid to liquid state, flows into void spaces, and then solidifies upon cooling, eliminating porosity and achieving full densification.
2Manufacturing precision
If Selective Laser Melting is used to manufacture components, then particles are completely melted and fuse together, but directional crystal microstructure orientation results in non-uniform strength properties
Solution Approach 1:
The patent applies local quality by differentiating the thermal treatment of different materials in the powder mixture. The braze particles are selectively melted while parent particles remain solid, creating localized liquid phases that fill gaps without imposing directional solidification patterns on the entire component, thus achieving uniform strength properties.
Solution Approach 2:
The patent uses braze material as an intermediary substance that facilitates bonding between parent particles. The braze melts, flows into voids, and solidifies to create bonds without requiring the parent particles to melt and form directional crystal structures, thereby achieving both densification and uniform strength.
3Manufacturing precision
If braze particles are melted to fuse parent core particles, then full densification is achieved, but the energy source temperature must be precisely controlled below the melting point of parent core particles
Solution Approach 1:
The patent uses composite materials by combining parent core particles with braze particles having different melting points. This material selection allows the energy source to selectively melt the braze material while leaving parent particles solid, achieving densification through controlled temperature ranges that fill voids without requiring excessive temperature control complexity.
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 method achieves full densification and uniform strength in components by fusing parent core particles with braze material, overcoming the limitations of voids and directional strength issues in existing techniques, and allows for the use of a wider variety of materials in additive manufacturing.
Implementation Method 1
the energy source is set above the melting point of the braze particles but below a melting point of the parent core particles, allowing the braze particles to melt
Implementation Method 2
allowing the braze particles to melt and distribute by capillary action to fuse the parent core particles
Implementation Method 3
applying the energy source to the powder and allowing the heated powder to solidify
Data Source
AI summary
A method of selective laser brazing is provided. The method includes providing a powder including a plurality of parent core particles and a plurality of braze particles, setting a temperature of an energy source, applying the energy source to the powder, and allowing the heated powder to solidify. The plurality of parent core particles are fused together by the plurality of braze material into a desired component.