Sensor-Guided Laser Removal of Heat Checking on Aluminum Castings
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Solution Overview
Problem
The casting process is hindered by heat checking, which results in surface cracks and reduced workability due to thermal fatigue, and existing removal methods like mechanical grinding are time-consuming, costly, and space-intensive, with safety concerns from using aluminum powder.
Innovation Solution
A system utilizing a beam of laser light to selectively remove heat checking from a casting surface, guided by a robotic arm and heat check sensor, allowing for precise and automated removal with minimal material loss and improved surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical grinders are used to remove heat checking, then heat check features can be removed from the casting surface, but the process becomes time-consuming and requires significant floor space
Solution Approach 1:
The patent replaces mechanical grinding systems with a laser-based thermal processing system. The laser beam delivers concentrated thermal energy to melt and remove heat check features without mechanical contact, eliminating the time-consuming nature of mechanical grinding while reducing floor space requirements through a more compact laser system setup
2Manufacturing precision
If mechanical grinders are used to remove heat checking, then heat check features can be removed, but expensive capital investment and significant floor space are required
Solution Approach 1:
The patent substitutes complex mechanical grinding equipment with a laser-based system that requires less capital investment and occupies minimal floor space. The laser system comprises a laser source, positioning system, and control unit, eliminating the need for large mechanical grinders and associated infrastructure
Solution Approach 2:
The patent changes the fundamental processing parameter from mechanical force to thermal energy. By using laser radiation to melt and remove material through thermal effects, the system achieves heat check removal without the complex mechanical systems, reducing both capital investment and space requirements
3Productivity
If aluminum powder is used in the removal process, then material can be removed, but safety concerns arise due to flammability and explosiveness
Solution Approach 1:
The patent replaces processes that may involve aluminum powder with a laser-based thermal removal system. The laser directly melts and vaporizes heat check features without requiring combustible materials, eliminating safety hazards associated with aluminum powder handling while maintaining efficient material removal rates
Solution Approach 2:
The patent converts the potential harm of using combustible materials like aluminum powder into a benefit by employing a non-combustible laser-based approach. The laser energy itself becomes the tool for material removal, eliminating the need for hazardous chemicals or powders while achieving the desired productivity
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 laser-based system efficiently and accurately removes heat checking, reducing surface porosity and aesthetic issues while minimizing time, expense, and space requirements, and eliminating the risks associated with aluminum powder handling.
Implementation Method 1
projecting a beam of laser light onto regions of the casting that have heat checking to melt and remove the heat check feature
Implementation Method 2
projecting a beam of laser light onto regions of the casting that have heat checking to melt and remove the heat check feature
Data Source
Figure 1A
Figure 1B~1C
Figure 1D
AI summary
A system for removing a heat check feature on an aluminum casting formed by a high pressure die casting process is provided. The system includes a laser source, a robotic arm, and a heat check sensor. The heat check sensor develops a surface profile of at least part of the casting and transmits heat check feature information to the laser source to project the beam of laser light thereon. The projection of the beam of laser light can be varied in time and power, which can depend on surface profile information obtained from the sensor. Once at least a portion of the heat check feature is removed, the casting is placed against another part such that the joint interface is primarily the portion where the heat checking has been removed. Self-piercing rivets are then driven into the casting and the part to permanently join them together.