Wide Laser Cladding Footprint for High-Rate Wire Deposition
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Solution Overview
Problem
Conventional welding and cladding techniques, such as hot wire TIG, are limited by small energy beam footprints, which restrict the deposition rate and quality of welds, especially on large surfaces, and do not efficiently distribute heat across the workpiece.
Innovation Solution
The use of a metalworking apparatus with a laser beam emitter and optical system to create a wide energy footprint, allowing for multiple feeder wires to be fed into a large, variable energy profile area, enabling wider and faster metal deposition with improved heat distribution and weld quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hot wire TIG welding with small energy beam footprint is used, then welding quality is maintained, but deposition rate and metal coverage are limited
Solution Approach 1:
The patent transforms the traditional small circular laser footprint into a wide rectangular footprint by modifying the optical system. This dimensional change in the energy beam distribution allows multiple filler wires to be simultaneously melted across a wider area, directly increasing deposition rate and metal coverage while maintaining weld quality through controlled energy distribution.
2Temperature
If conventional small footprint laser is used, then heat concentration is achieved, but heat distribution across large surfaces is inefficient
Solution Approach 1:
The patent applies local quality by creating different energy density zones within the wide rectangular footprint. The optical system is designed to distribute laser energy non-uniformly across the width, with higher energy concentration at the edges where filler wires are positioned, ensuring efficient melting and heat distribution across large workpiece surfaces while maintaining localized temperature control for weld quality.
3Productivity
If wide energy footprint is implemented, then metal coverage and deposition rate increase, but energy distribution uniformity becomes challenging
Solution Approach 1:
The patent implements dynamics by making the energy distribution adjustable and controllable. The optical system allows dynamic adjustment of the laser footprint shape and energy density profile to match the specific requirements of different welding applications. This enables optimization of both wide coverage and uniform energy distribution by adapting the energy profile to the workpiece geometry and material properties.
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 increased metal coverage and deposition rates, achieving wider welds or clads with improved uniformity and reduced porosity, enhancing the efficiency and quality of welding, cladding, and additive manufacturing processes.
Implementation Method 1
a laser is used to melt a power on a workpiece
Implementation Method 2
The wire is typically fed in front of or behind a high-power energy source such as a laser or plasma that further melts the wire material along with the base metal of the workpiece to produce a weld or clad
Implementation Method 3
The resistive heating of the metal filler wire reduces the amount of heat needed for the base metal of a workpiece to which the heated wire is applied
Implementation Method 4
a metal filler or feeder wire is heated, usually resistively, by passing an electrical current through it
Implementation Method 5
an optical system to shape the beam to have a controlled footprint
Data Source
AI summary
A welding or cladding apparatus in which one or more energy beam emitters are used to generate a wide beam spot transverse to a welding or cladding path, and one or more wide feeders feed wire to the spot to create a wide welding or cladding puddle.