Wide Laser Cladding Head With Segmented Powder Feeding
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Solution Overview
Problem
Existing technologies lack a device that integrates wide laser beam laser additive manufacturing and cladding with high-throughput optimization and accurate composition control, restricting high-efficiency protection for large-scale workpieces in extreme environments.
Innovation Solution
A wide laser beam high-throughput additive-manufacturing and cladding device with a wide laser beam cladding head, high-throughput powder-feeding system, and mechanical motion system, featuring a rectangular powder-feeding outlet divided into small holes and a gas-powder mixing path structure for synchronous powder feeding, allowing accurate control of powder composition and continuous or boundary-leap changes in cladding zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional laser cladding technology is used, then processing can be conducted on workpieces, but processing efficiency is low and it cannot meet high-throughput requirements
Solution Approach 1:
The powder-feeding outlet is segmented into multiple small holes (e.g., 7 holes) arranged in specific patterns. This segmentation allows powder to be fed through multiple channels simultaneously, increasing the throughput of powder delivery to the cladding zone while maintaining precise control over powder distribution
Solution Approach 2:
The patent transitions from traditional single-point or linear laser cladding to a two-dimensional wide beam cladding approach. The wide laser beam (20mm to 40mm width) enables simultaneous processing across a broad area, dramatically increasing productivity by processing entire surfaces or large zones in a single pass rather than point-by-point
2Productivity
If wide laser beam cladding is used to increase processing area, then productivity improves, but powder utilization rate decreases
Solution Approach 1:
Different regions of the powder-feeding outlet are designed with different hole distributions and characteristics. The hole patterns are optimized to match the local requirements of different zones within the wide beam cladding area, ensuring uniform powder distribution and complete utilization across the entire 20mm to 40mm beam width
Solution Approach 2:
Multiple powder streams from different holes are merged and converged into the wide laser beam cladding zone. The gas-powder mixing path structure combines powder from multiple sources efficiently, ensuring all powder is utilized within the cladding process with minimal waste
3Adaptability or versatility
If fixed-form powder feeding nozzle is used, then device structure is simple, but adaptability to different processing requirements is poor
Solution Approach 1:
The nozzle design incorporates adjustable elements that allow dynamic modification of powder feeding characteristics. The ability to adjust powder feeding parameters enables the system to adapt to different cladding requirements, material types, and processing conditions without requiring complete nozzle replacement
Solution Approach 2:
The wide beam cladding device with segmented powder feeding is designed to perform multiple functions: it can process different materials, accommodate various cladding geometries, and adjust to different productivity requirements. This multi-functional design enhances versatility while maintaining a relatively compact and integrated structure
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
Enables high-efficiency additive manufacturing and cladding with a 20 mm to 40 mm beam width, improving powder utilization to 95% and enabling rapid optimization of material compositions for large-scale workpieces in extreme environments.
Implementation Method 1
a laser input from an external optical fiber passes through a collimating lens, a diffractive optical element (DOE), a concentrating lens, and a protective lens successively, and a wide laser beam is output
Implementation Method 2
the powders are heated and melted at the moment of entering the wide laser beam, then partially-melted powders are mixed with each other, and the powders are fully merged and melted before reaching a workpiece
Implementation Method 3
a collimated laser beam is accurately shaped into a rectangular beam from a circular beam through the DOE
Data Source
AI summary
The present disclosure relates to a wide laser beam high-throughput additive-manufacturing and cladding device and a working method thereof, and belongs to the field of surface engineering for materials. In the present disclosure, an external optical fiber is connected to an optical fiber interface to input a laser, and the laser passes through a collimating lens, a diffractive optical element (DOE), a concentrating lens, and a protective lens successively, such that a wide laser beam laser beam is output at an outlet of a nozzle, with a beam width of 20 mm to 40 mm. Two powder-feeding tanks are connected to a powder-feeding interface of the nozzle through a powder-feeding pipe. A cooling water pipe is connected with a plurality of water-cooling interfaces to form a circulation. An external shielding gas is connected to a shielding-gas interface to provide a central shielding gas.