3D Powder Preheating With Spiral Electron Beam Scanning

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Solution Overview

Problem

Existing three-dimensional shaping devices face challenges in uniformly heating powder materials during preheating due to response delays and uneven heat input, leading to incomplete or excessive irradiation areas when using electron beams.

Innovation Solution

The use of an electron beam emitting unit that moves the irradiation position in a spiral pattern for preliminary heating, reducing response delays and ensuring uniform heat distribution by maintaining a consistent path without steep changes, thus preventing uneven heat input.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the electron beam scanning paths are set away from each other by a predetermined distance to curb influence of electric charges, then the reliability of preheating is improved, but the manufacturing precision of uniform heat input deteriorates

Engineering Contradiction:

Improvepreheating reliabilityVSAvoiduniform heat input

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies spiral scanning paths instead of linear or grid patterns, creating a curved continuous trajectory that eliminates abrupt directional changes. This spiral curvature ensures uniform electron beam distribution while maintaining reliable preheating by avoiding charge accumulation at sharp turning points.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The electron beam scanning system dynamically adjusts its trajectory to follow a spiral pattern with continuously varying direction, rather than static predetermined paths with fixed turning points. This dynamic scanning approach maintains consistent heat input while preventing charge accumulation issues.

Inventive Principle:

Principle #15Dynamics

2Productivity

If the electron beam scanning speed is increased to improve productivity, then the productivity of preheating is improved, but the manufacturing precision of uniform heat distribution deteriorates due to response delay

Engineering Contradiction:

Improvepreheating speedVSAvoiduniform heat distribution

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The spiral scanning path with gradual curvature changes allows the electron beam to maintain higher speeds while avoiding abrupt turning movements. The continuous curved trajectory reduces response delay effects, enabling both high productivity and uniform heat distribution simultaneously.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The spiral scanning pattern预先 distributes heat more evenly across the powder material surface before melting begins, ensuring uniform preliminary heating that prepares the material for subsequent high-speed processing without causing localized overheating or underheating.

Inventive Principle:

Principle #10Preliminary action

3Area of stationary object

If the electron beam scanning paths have sharp turning points to cover the irradiation region efficiently, then the area coverage is improved, but the manufacturing precision of heat input uniformity deteriorates due to response delay

Engineering Contradiction:

Improveirradiation region coverageVSAvoidheat input uniformity

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The spiral scanning trajectory replaces sharp turning points with smooth continuous curves, eliminating the response delay issues at corners while still achieving complete coverage of the irradiation region. The gradual curvature changes allow the electron beam to maintain precision throughout the entire scanning area.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 approach allows for effective preliminary heating of powder materials, reducing the likelihood of incomplete or excessive irradiation and ensuring a uniform heat input, which is essential for shaping three-dimensional articles efficiently.

Implementation Method 1

irradiating the powder material with an electron beam

Methodology Applied

Scientific EffectElectron beam irradiation: Electron Beam

Implementation Method 2

performing preliminary heating of the powder material by irradiating the powder material with the electron beam

Methodology Applied

Scientific EffectElectron beam heating: Heating

Implementation Method 3

melting the powder material in order to shape the article

Methodology Applied

Scientific EffectElectron beam melting: Melting

Implementation Method 4

irradiating the powder material with an electron beam and melting the powder material

Methodology Applied

Scientific EffectThermal energy concentration: Heating

Data Source

PatentUS12005635B2Three-dimensional shaping device and three-dimensional shaping method

Publication Date: 2024.06.11 IHI CORP

AI summary

A three-dimensional shaping device shapes a three-dimensional article by irradiating a powder material with an electron beam and melting the powder material. The three-dimensional shaping device includes an electron beam emitting unit emitting the electron beam, melting the powder material in order to shape the article, and performing preliminary heating of the powder material by irradiating the powder material with the electron beam before the article is shaped. The electron beam emitting unit moves an irradiation position of the electron beam in a spiral pattern when the powder material is irradiated with the electron beam for preliminary heating.