In-Situ Sintered Wire Feeding for Superalloy Laser Repair
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Solution Overview
Problem
Laser metal deposition processes using powdered materials are inefficient due to material loss and contamination issues during the spraying process, particularly when repairing high-strength, low-ductility superalloys.
Innovation Solution
A system and method utilizing a sintered wire created by mixing and heating powders in a pressure vessel, which is then continuously fed to a laser wire welding system for additive manufacturing or repair, reducing material loss and contamination by using a sintered wire with a composition matching the base material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If powdered materials are used in laser metal deposition, then the process can be applied to superalloy components, but material loss occurs during the spraying process
Solution Approach 1:
The invention changes the physical state and form of the additive material from loose powder to a sintered wire or rod. This parameter change eliminates material loss during spraying by directly feeding the sintered material into the melt pool through wire feeding mechanisms, thereby resolving the contradiction between adaptability to superalloys and material loss.
Solution Approach 2:
The invention introduces an intermediary sintering process that transforms powder materials into a wire or rod form. This intermediary step acts as a mediator between the powder material and the deposition process, eliminating the spraying step that causes material loss while maintaining the ability to process superalloy materials.
2Ease of manufacture
If powdered materials are used in laser metal deposition, then additive manufacturing can be performed, but contaminants may be deposited along with the powdered materials
Solution Approach 1:
The invention changes the physical form of the additive material from loose powder to a sintered wire or rod. This parameter change eliminates the contamination issue by removing the unconfined nature of powdered materials during the deposition process, while preserving additive manufacturing capability through direct wire feeding.
Solution Approach 2:
The sintering process serves as an intermediary that transforms powder materials into a controlled wire or rod form. This intermediary step eliminates contaminants by confining the material during sintering and feeding, while maintaining the ability to perform additive manufacturing of superalloy components.
3Ease of operation
If traditional laser metal deposition with powdered materials is used, then the process is simple to operate, but material efficiency is low
Solution Approach 1:
The invention changes the material delivery form from sprayed powder to fed sintered wire/rod. This parameter change improves material efficiency by eliminating spray-related material loss, while the process remains operationally simple through automated wire feeding systems.
4Ease of manufacture
If powdered materials are used in laser metal deposition, then the process can deposit additive material, but ductility of the deposited material is reduced
Solution Approach 1:
The invention changes the physical form of the additive material from powder to sintered wire or rod. This parameter change improves ductility by eliminating the unconfined nature of powdered materials during deposition, which causes defects, while maintaining the ability to deposit additive material for superalloy components.
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 process enhances material efficiency and reduces contamination by directly depositing a sintered wire with a composition matching the base material, improving the additive manufacturing and repair of superalloy components with reduced material loss and improved ductility.
Implementation Method 1
a heating device contained within the pressure vessel heats the mixture so that liquid phase sintering occurs and a sintered wire is created
Implementation Method 2
The laser metal deposition system directs a laser beam from the laser wire welding system towards a base material of the superalloy component which forms a melt pool on the base material
Data Source
Figure 1
Figure 2~3
AI summary
A system for manufacturing of a sintered wire and in-situ feeding to a laser wire welding system is presented. The system includes a pressure vessel connected to a powder feed system for delivering at least two powders to a powder mixing zone of the pressure vessel. The at least two powders are mixed via a rotating cone in the pressure vessel. After mixing, a heating device contained within the pressure vessel heats the mixture so that liquid phase sintering occurs and a sintered rod is created. The sintered wire is continuously fed to a laser metal deposition system for depositing a layer of additive material on a base material. A method of additively manufacturing or repairing a superalloy component is also presented.