In-Situ Sintered Wire Feeding for Low-Loss Laser Metal Deposition
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Solution Overview
Problem
Laser metal deposition processes using powdered materials for superalloy repair and manufacturing are inefficient due to material loss and contamination issues, as they lack confinement and often deposit unwanted contaminants.
Innovation Solution
A system and method utilizing a pressure vessel to mix and heat powders for in-situ manufacturing of a sintered wire, 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 consistent chemical composition similar to the base material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If powdered materials are used in laser metal deposition process, then the process can be applied for additive manufacturing and repair, but material loss occurs during spraying and contaminants are deposited
Solution Approach 1:
The invention changes the physical state and form of the additive material from loose powder to a confined wire format. This parameter change eliminates material loss during spraying while maintaining the applicability of the LMD process for additive manufacturing and repair operations
Solution Approach 2:
The invention creates a composite wire structure consisting of a core material surrounded by a coating layer. This composite structure allows the wire to be fed through the laser beam without disintegration while maintaining consistent chemical composition similar to the base material, thereby eliminating contamination issues
2Adaptability or versatility
If powdered materials are used in laser metal deposition process, then the process can be applied for additive manufacturing and repair, but contaminants are deposited along with the powdered materials
Solution Approach 1:
The invention creates a composite wire structure with a core and coating layer designed to match the base material composition. This eliminates contamination because the wire material is consistent with the substrate, unlike loose powder which can introduce foreign contaminants
Solution Approach 2:
Changing from powder to wire format fundamentally alters how material is delivered to the melt pool. The wire format ensures only the intended additive material is deposited, eliminating the contamination problem inherent in powder-based systems
3Loss of substance
If sintered wire is manufactured in-situ and fed continuously to laser wire welding system, then material efficiency is enhanced and contamination is reduced, but process complexity increases
Solution Approach 1:
The invention merges the wire manufacturing process with the additive manufacturing process by integrating the sintering zone directly into the LMD system. This allows in-situ creation of the sintered wire and continuous feeding to the laser welding zone, achieving material efficiency without requiring separate external wire production equipment
Solution Approach 2:
The system performs self-service by manufacturing its own wire feedstock on-demand within the pressure vessel. The sintering process automatically converts powder to sintered wire format as needed, eliminating the need for pre-manufactured wire and reducing material waste
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 consistent composition, improving the additive manufacturing and repair of superalloy components with reduced material loss and contamination.
Implementation Method 1
The mixture is then heated by a heating device so that liquid phase sintering occurs creating a sintered wire
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
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.