Multi-Angle Shielding Gas Nozzle for Wire Shadow Area Coverage
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Solution Overview
Problem
In laser metal forming using a wire material, the shielding gas supply axis and wire feed axis being non-coaxial leads to obstruction of the shielding gas by the wire, resulting in incomplete antioxidation of the processing area, known as the 'shadow area', which hampers effective oxidation prevention.
Innovation Solution
A shielding gas nozzle design featuring a wire feed line inclined at an angle θ, with a first gas ejection hole jetting shielding gas at an angle equal to or less than θ to the base material surface and a second gas ejection hole jetting shielding gas at a different direction, ensuring the intersection of these axes is positioned below both ejection holes, allowing the shielding gas to be supplied to the processing area from multiple angles, thereby preventing oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single gas ejection hole is used with the shielding gas supply axis and wire feed axis being non-coaxial, then the wire feed operation is simplified, but the shielding gas supply is blocked by the wire in the shadow area, resulting in incomplete oxidation prevention
Solution Approach 1:
The single gas ejection hole is divided into multiple gas ejection holes (first gas ejection hole and second gas ejection hole) with different ejection directions. The first gas ejection hole ejects shielding gas in a direction equal to or less than the wire inclination angle θ to the base material surface, while the second gas ejection hole ejects shielding gas in a different direction. This segmentation allows shielding gas to reach both the front and shadow areas of the wire, ensuring complete oxidation prevention while maintaining operational simplicity
Solution Approach 2:
The solution introduces multi-directional gas ejection by positioning gas ejection holes at different angular orientations rather than using a single axial ejection. The first gas ejection hole operates at an angle ≤θ to the base material surface, while the second gas ejection hole operates at a different angle, creating a three-dimensional shielding gas distribution pattern that covers the shadow area without complicating the wire feed operation
2Area of stationary object
If the shielding gas is jetted at a high angle to the base material surface, then the shielding gas can reach further into the processing area, but the gas flow is blocked by the wire, creating shadow areas with insufficient shielding
Solution Approach 1:
Different regions of the processing area are provided with shielding gas at different angles optimized for their specific needs. The first gas ejection hole provides shielding gas at an angle ≤θ to cover areas where the wire does not obstruct, while the second gas ejection hole provides shielding gas at a different angle to specifically cover the shadow area behind the wire. This localized optimization ensures comprehensive coverage without blockage issues
3Reliability
If multiple gas ejection holes with different angles are used, then complete shielding coverage is achieved, but the nozzle structure becomes more complex
Solution Approach 1:
The nozzle structure integrates multiple gas ejection holes with different ejection angles into a single universal component. The first gas ejection hole and second gas ejection hole are both part of the same nozzle assembly, allowing the nozzle to perform multiple functions (ejecting gas at different angles) simultaneously. This multi-functionality design achieves complete shielding coverage while avoiding the need for separate nozzle components, thereby controlling structural 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
This configuration ensures comprehensive air shielding during laser metal forming, preventing oxidation of beads and the base material by ensuring continuous shielding gas supply even in areas obstructed by the wire, thereby maintaining a protective atmosphere.
Implementation Method 1
shielding gas that prevents such oxidation is supplied to the processing area and its vicinity
Data Source
AI summary
A shielding gas nozzle for metal forming includes a wire feed line being a path to feed a wire at an inclination angle θ, a first gas ejection hole to jet a shielding gas at an angle equal to or less than the inclination angle θ, and a second gas ejection hole to jet the shielding gas in a direction different from that of the first gas ejection hole. The first gas ejection hole jets the shielding gas toward an intersection along a direction in which the absolute value of the angle to the wire feed direction is less than 90 degrees, and the second gas ejection hole jets the shielding gas toward the intersection along a direction in which the absolute value of the angle to the wire feed direction when viewed in the direction perpendicular to the base material surface is greater than 90 degrees.