X-ray Tube Target Laser Deposition for Reliability
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Solution Overview
Problem
Newer x-ray tubes face reliability and performance issues due to high peak power leading to increased target temperatures, and existing deposition processes are inefficient, wasting materials and limiting alloy options, especially with tantalum and Ta-alloys due to powder auto-inflammability.
Innovation Solution
A method and apparatus using a laser beam or other heating mechanism to fuse materials onto an x-ray tube target substrate, allowing for layered or graded structures and complex geometries, and enabling the use of solid stock materials like tungsten, molybdenum, and tantalum alloys, which are not feasible with traditional powder-based processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If higher peak power is applied to the x-ray tube, then the power output and imaging capability are improved, but the target temperature increases leading to reduced reliability and component life
Solution Approach 1:
The patent applies laser beam parameters (power, duration, focal position) to precisely control the melting and deposition of target track material. By changing laser parameters, the process achieves controlled material fusion and repair of the target track surface, allowing the x-ray tube to operate at higher peak powers while maintaining target integrity and reliability
2Ease of manufacture
If traditional powder deposition processes are used to apply target track material, then material can be deposited onto the target, but large volumes of expensive materials are wasted and alloy options are limited due to powder auto-inflammability
Solution Approach 1:
The patent replaces traditional mechanical powder deposition processes with a laser beam-based material fusion process. Solid target track material is directly fused onto the target surface through controlled laser heating, eliminating the need for powder application and associated material waste. This substitution enables precise material placement with minimal waste and expands alloy options beyond what is feasible with powder processes
Solution Approach 2:
The patent performs laser-based material deposition in a vacuum environment, which prevents oxidation and auto-inflammability of materials during the process. This inert environment enables the use of reactive materials and alloys (such as tantalum and its alloys) that would be difficult or impossible to process using traditional powder deposition methods that require atmospheric conditions
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 improves the fabrication and repair of x-ray tube targets, reducing material waste, extending component life, and enabling the use of previously unrecoverable targets by forming high-density coatings with enhanced mechanical properties.
Implementation Method 1
direct a beam of energy toward an x-ray tube target and direct a solid stock material toward the beam of energy to cause the solid stock material to melt and deposit as a melted material on the x-ray tube target
Implementation Method 2
cause the solid stock material to melt and deposit as a melted material on the x-ray tube target
Data Source
AI summary
A system for applying a target track material to an x-ray tube target includes a controller configured to direct a beam of energy toward an x-ray tube target, and direct a solid stock material toward the beam of energy to cause the solid stock material to melt and deposit as a melted material on the x-ray tube target.