Vibrating DED Nozzle Assembly for Uniform Powder Flow
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Solution Overview
Problem
In directed energy deposition, there is a need for an improved nozzle assembly that prevents the accumulation of melted powder at the nozzle tip, which affects the uniformity of powder distribution and requires frequent cleaning, leading to reduced nozzle operation time and compromised workpiece quality.
Innovation Solution
A nozzle assembly with a vibrator that applies a controlled vibration to the nozzle, using a ring-shaped silicone body and an electric motor to move a weight perpendicular to the nozzle's axis, which dislodges and prevents powder adhesion, reducing agglomeration and non-uniformity, and is configured with an annular orifice surrounding the energy beam opening to facilitate efficient powder and gas stream delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If vibration is applied to the nozzle, then powder accumulation is prevented and operation time is extended, but device complexity increases due to additional vibrator components
Solution Approach 1:
The vibrator is disposed within the nozzle assembly structure, with the electric motor and movable weight integrated into the existing nozzle components. The ring-shaped silicone body contacts the external surface of the nozzle, nesting the vibration mechanism within the nozzle's frustoconical structure rather than adding external attachments.
Solution Approach 2:
A vibrator comprising an electric motor and a movable weight is used to impart mechanical vibration to the nozzle. The electric motor moves the weight back and forth along a direction perpendicular to the longitudinal axis of the nozzle, creating vibration that prevents powder accumulation and adhesion at the nozzle tip.
2Manufacturing precision
If a gap-defined orifice is used instead of a solid nozzle tip, then powder distribution uniformity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The nozzle is divided into an inner body and an outer body that are peripherally disposed around the inner body, creating a gap between them that forms the orifice. This segmentation allows the orifice to be defined by the gap rather than requiring precision machining of a solid tip, improving powder distribution while facilitating manufacturing.
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 vibration enhances nozzle operation time by preventing powder accumulation, improving powder distribution uniformity and workpiece quality by reducing agglomeration and maintaining consistent material flow, thereby extending the time before nozzle cleaning is required.
Implementation Method 1
a vibrator configured to apply a vibration to the nozzle... the vibration is applied so as to effect at least one of the following: (a) dislodging of powder adhering to the nozzle, (b) preventing powder from adhering to the nozzle, (c) reducing non-uniformity of a distribution of powder from the nozzle, and (d) acting against formation of an agglomeration of melted powder on the nozzle
Implementation Method 2
the material is melted by the energy beam... the energy beam comprises a laser beam
Implementation Method 3
the orifice defined by the gap and the opening through which the energy beam exits the nozzle are configured such that the material is melted by the energy beam
Data Source
AI summary
A directed energy deposition nozzle assembly including (1) a nozzle configured to dispense material for directed energy deposition, wherein the material comprises one or more of metallic powder, ceramic powder, and glass powder, and wherein (a) the nozzle has an orifice through which the material exits the nozzle, wherein the nozzle comprises an inner body and an outer body that is peripherally disposed around the inner body, and wherein the orifice is defined by a gap between the inner body and the outer body, or (b) the nozzle comprises a plurality of orifices through which the material exits the nozzle, and (2) a vibrator configured to apply a vibration to the nozzle.