WO2018134605A1 - Ensemble de distribution de poudre - Google Patents
Ensemble de distribution de poudre Download PDFInfo
- Publication number
- WO2018134605A1 WO2018134605A1 PCT/GB2018/050154 GB2018050154W WO2018134605A1 WO 2018134605 A1 WO2018134605 A1 WO 2018134605A1 GB 2018050154 W GB2018050154 W GB 2018050154W WO 2018134605 A1 WO2018134605 A1 WO 2018134605A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- powder delivery
- powder
- delivery assembly
- nozzles
- nozzle
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/34—Laser welding for purposes other than joining
- B23K26/342—Build-up welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/14—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
- B23K26/144—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor the fluid stream containing particles, e.g. powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/14—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
- B23K26/1462—Nozzles; Features related to nozzles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/205—Means for applying layers
- B29C64/209—Heads; Nozzles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
Definitions
- This invention relates to a powder delivery assembly, and in particular, but without limitation, to a powder delivery assembly comprising a plurality of outlets arranged to provide converging streams of powder; and/or a thermally-improved powder delivery nozzle.
- a powder delivery nozzle or assembly such as that used in a laser-assisted blown powder deposition system, has the ability to deliver a gas-fluidised (usually by an inert gas) powder stream to a melt pool on a surface.
- the melt pool is typically created by a defocussed laser beam, and by adding powder to the melt pool and subsequently allowing it to solidify, it is possible to build parts or components layer-wise using techniques that are generally well-understood in the field of additive manufacturing. Blown powder additive manufacturing techniques are in widespread use nowadays for manufacturing coatings or parts out of metals.
- a laser/powder delivery nozzle assembly as described herein is moved relative to the surface, depositing a layer of solidified material in its wake in a manner similar to that of welding with a filler material.
- the height/thickness of the deposited layer thus produced typically increases with increased powder flow rate (or vice-versa) - the more material that is added per unit of time for a given traverse speed, the thicker the deposited layer. Additionally or alternatively, the height/thickness of the deposited layer thus produced typically increases with decreased relative traverse speed (or vice-versa) - the slower the assembly moves over the substrate, the longer the assembly resides over any given point, thereby increasing the amount of powder deposited, per unit length of relative traverse.
- a powder delivery nozzle that can, in certain cases, achieve consistent delivery of powder per unit length traversed- independent of relative part movement.
- a powder delivery nozzle that can, in certain cases, control of the height of the deposited layer to achieve consistent delivery of powder per unit length traversed- independent of relative part movement.
- Another aspect of the invention provides an improved powder delivery nozzle for blown powder laser additive manufacture for delivering a mixture of powder particles and carrier gas (collectively a "powder stream") to a laser-generated melt pool while dynamically controlling the amount of powder delivered to the melt pool region and hence the height of the deposited layer.
- a powder delivery nozzle for blown powder laser additive manufacture for delivering a mixture of powder particles and carrier gas (collectively a "powder stream") to a laser-generated melt pool while dynamically controlling the amount of powder delivered to the melt pool region and hence the height of the deposited layer.
- a powder delivery system comprising a central aperture through which, in use, a heating beam is arranged to pass along a beam axis, and a plurality of powder delivery nozzles, each having an outlet through which a stream of powder flows along a respective powder trajectory, the powder delivery nozzles being arranged such that their respective powder trajectories substantially intersect the beam axis.
- a yet further aspect of the invention provides a powder delivery assembly comprising: a central bore with an outlet through which, in use, a heating beam is arranged to pass along a beam axis coaxial with the central bore, and a plurality of powder delivery nozzles, each powder delivery nozzle comprising a bore and an outlet through which bore a stream of gas-powder flows, in use, along a respective powder trajectory which is coaxial with the respective powder delivery nozzle bore, wherein the powder delivery nozzles are arranged such that their respective powder trajectories substantially intersect the beam axis downstream of the central bore's outlet.
- the powder delivery system or assembly of the invention may incorporate various improvements over existing powder delivery assemblies, such as: an improved angle for introduction of the powder streams to the melt pool, design features to reduce heating of the nozzle from the melt pool and hence improve powder stream geometry and associated laser coupling efficiencies.
- the powder delivery nozzles are equispaced around the central aperture, that is to say, with substantially equal angular separations about the beam axis.
- three or more powder delivery nozzles are provided. Most preferably, there are four powder delivery nozzles arranged at 90-degrees around the beam axis.
- the powder feed nozzles are suitably arranged at, or substantially at, between 40 and 44- degrees to a plane transverse to the beam axis.
- the powder feed nozzles are arranged at, or substantially at, 42-degrees to a plane transverse to the beam axis.
- a 42-degree incident angle causes the powder to impinge on the melt pool at an angle which allows the gas being fed along the laser beam axis to compress the melt pool redirect divergent lower velocity powder particles comprising the upper part of each powder stream back into the main body of each powder stream, both increasing the density and increasing the definition of the upper boundary of the combined powder streams at their intersection with the melt pool, and thus height-limiting the resultant layer produced it.
- the laser is able to heat the melt pool more efficiently, and because the beam-axis gas flow assists in constraining the upper vertical divergence of powder streams powered in the melt pool, rather than having to reply on relatively high opposing gas flows from the powder delivery nozzles themselves, the gas flow rates through the powered delivery nozzles can be reduced also.
- the invention is able to utilise the effect of the axial gas flow to achieve similar or better melt pool powder stream containment, and because the interaction zone between the laser and the melt pool is thus significantly reduced in volume, further reducing the attenuation of the incident laser beam is minimised compared to those systems feeding powder at higher incident angles. Further, this design results in most of those powder particles which have not been incorporated into the melt pool also bypassing the beam itself, allowing recovery and reuse of those powder particles.
- a plurality of tubes or pipes of typical bore 1.5-2mm, carrying a "powder stream" arranged with radial symmetry around the beam axis are provided, which have their long axes at an angle of 40-42 degrees to the radial plane such that these long axes converge to the beam axis at a point typically 15mm from the opening of central aperture.
- the heating beam suitably comprises a laser beam.
- a possible advantage of the invention is that because the powder is fed into the heating (laser) beam from different angles, the powder delivery assembly is effectively rendered more omnidirectional.
- the powder delivery assembly of the invention can be less sensitive, or insensitive to the traverse direction/acceleration with regard to powder delivery consistency than known powder delivery nozzles.
- a powder splitter is suitably provided upstream of the nozzles to separate a feed of powder into a respective number of similar or substantially identical flow streams.
- An example of such a splitter is described in our co-pending patent application: GB 1620735.9 (6 December 2016).
- the powder delivery assembly comprises design features that minimise the effects (upon both the nozzle and the process) of incident thermal radiation and convected hot gases emitted from the laser-heated melt-pool. These design features, include, but are not limited to, any one or more of the group comprising:
- the nozzle of, or coating it with, a material that reflects thermal radiation such as infrared light.
- the thermal radiation/infrared reflective material may be copper or a copper alloy; aluminium or aluminium alloy or other materials with relativity high reflectivity to infrared. Additionally or alternatively, parts of the surface of the nozzle which are exposed to thermal radiation, in use, may be polished, for example, to a smooth and/or mirror finish so as to facilitate reflection of thermal radiation.
- the body of the system being designed such that hot gas convected from the area heated by the laser is directed past the nozzle body due to streamlining.
- Streamlining in this way may allow the hot gasses produced, in use, by the melt pool (i.e. "convective gas streams") to pass freely around and over the nozzle, thus reducing or minimising convective heat transfer into the nozzle.
- Streamlining may also have the advantage of reducing or preventing derangement of the powder streams incident to the melt pool as a result of these convective gas streams;
- the high thermal conductivity material may be copper or its alloys, aluminium or its alloys or other materials chosen for high thermal conductivity;
- each component can increase in cross-section and material bulk in the direction of heat flow away from that part closest to the melt pool, in order to facilitate rapid cooling.
- Figure 1 is a side view of a powder feed comprising a powder delivery assembly in accordance with the invention
- Figure 2 is a view from below of the powder feed of Figure 1;
- Figure 3 is a cross-section of Figure 2;
- Figures 4 and 5 are views of the powder feed showing its streamlined design for improved bypass of hot gas convective flow and presentation of oblique surfaces to incident thermal radiation;
- Figure 6 is a side view showing different areas of the powder feed
- FIGS 7, 8 and 9 are, respectively, perspective, side and bottom views of an alternative powder feed assembly in accordance with the invention.
- Figure 9 is an illustration of the effect of the streamlining of the powder delivery assembly shown in Figures 1 to 6;
- Figure 10 is an illustration of the effect of the streamlining of the powder delivery assembly shown in Figures 7 to 9;
- Figure 11 is an illustration of the radiative heating effects on a powder delivery assembly shown in Figures 7 to 9.
- a powder feed 10 comprises a powder delivery assembly 12 according to the invention.
- the powder feed 10 is mounted substantially vertically and has a central tube 14 through which, in use, a focussed laser beam 16 passes.
- the laser beam 16 has a beam axis 18, which passes through an aperture 20 at the tip of the central tube 14.
- the powder delivery assembly 12 is formed by the central tube 14, and four radially symmetric powder feed nozzles 22, which have a bore diameter of about 1.5mm to 2mm. This particular dimension has been usefully found to minimise the width of the powder stream emitted from each of the nozzles 22, and hence increase catchment efficiency for relatively small melt pool diameters.
- the powder feed nozzles 22 are arranged at 42 degrees to a plane transverse to the beam axis 18. The (substantially) 42-degree angle has been found, empirically, to provide optimum results in limiting the layer thickness formed by the system.
- the powder feed nozzles 22 are fed, via powder feed tubes 26, which connect to respective outlets of a 4-way powder splitter 28, by a stream of powder-gas mixture, which has a laminar-flow powder gas mix fed through them. This results in a gas/powder stream delivered by each nozzle 22 along respective powder stream trajectories 30, which intersect the beam axis 18.
- the intersection point 32 is roughly, in use, the location of the melt pool formed by the system.
- powder flaring from the top of the powder stream consists of smaller particles than the bulk flow. This, coupled with the fact that particles traveling off-axis from the main stream (in the laminar flow regime), necessarily have lower particle velocities, results in the fact that powder flaring from the top of the powder stream has a lower momentum than that in the main part of the powder stream.
- An inert gas such as argon, is fed through the orifice 20 (in this case, having a 2mm diameter) at the tip of the central tube 14, which is, of course, coaxial with the laser beam.
- the inert gas upon exiting the orifice 20, diverges due to gas expansion, and this inert gas stream is thus directed towards the area where the powder-gas streams emitted from the powder feed nozzles 22 will intersect 32 at the position of the melt pool.
- the diverging inert gas flow referred to in the preceding paragraph is used to redirect the off- axis powder particles back into the main powder stream.
- a 'balance point' between the powder/gas mix flow rates and the coaxial gas flow rate can be obtained (dependent upon the density and size distribution of the powder), which will result in a refinement of the top boundary of the individual powder streams as they combine into a powder 'cloud'.
- the refinement of the top of the powder cloud boundary causes an abrupt reduction in powder catchment efficiency in a vertical plane at a fixed position relative to the powder feed nozzle 30.
- a deposited layer will build to the top of this interface, but cannot build any higher due to a lack of available powder.
- the height of the deposited layer is limited by the physical position of the powder feed nozzle and not by the other deposition parameters, allowing the layer height to be controlled by the programmed incremental step height per layer rather than vice versa.
- This type of powder delivery nozzle is therefore referred to as a "layer height-restricting powder delivery nozzle" and was first described in Fearon E, 'Laser Free Form Fabrication applied to the manufacture of metallic components' PhD thesis, University of Liverpool 2002.
- the "layer height-restricting nozzle" is modified slightly, such that no plane of the nozzle body 40 is directly incident to any thermal radiation which may be emitted in a hemispherical manner from the melt pool surface created by the laser beam passing through the nozzle 10.
- This measure of avoidance of absorption of incident radiation is enhanced by making the nozzle of, or coating it with, an infrared reflective material such as copper or its alloys, aluminium or its alloys or other materials with relativity high reflectivity to infrared.
- an infrared reflective material such as copper or its alloys, aluminium or its alloys or other materials with relativity high reflectivity to infrared.
- the body of the nozzle may be designed such that hot gas convected from the area heated by the laser is directed past the nozzle body due to streamlining, as indicated by 42 in the Figures. Possible effects upon the nozzle and process of these design features are such that:
- Temperature stabilization of the nozzle system described above has corresponding benefits to the stabilization of the powder cloud. Stabilization of the powder cloud maintains both consistency of layer height control by the method described above and the proportion of powder stream directed to the centre of the melt pool.
- the powder delivery assembly 12 has a central nozzle 100 and four powder delivery nozzles 22 arranged radially at 90-degree intervals around it.
- Each nozzle 100, 22 is part-conical with its narrow tip end pointing towards the melt pool (not shown) or intersection point 32.
- the tip 110 of each nozzle 100, 22 is rounded so as to present a rounded surface to the radiated heat emitted from the intersection point 32, thus reflecting radiated heat away; and also streamline the nozzles 100, 22 relative to gases moving away from the intersection point 32.
- the powder delivery nozzles 22 each have a central bore whose axes 102 intersect the beam axis 18 at the intersection point.
- the angle 104 between the delivery nozzles' central bore axes 114 and a normal to the beam axis 18 is 42-degrees - for the reasons previously stated.
- Each powder delivery nozzle 22 is supported on a respective rib 106, whose cross-sections are part-elliptical so as to present a rounded surface to the radiated heat emitted from the intersection point 32, thus reflecting radiated heat away; and also streamline the ribs 106 relative to gases moving away from the intersection point 32.
- the ribs 104 are formed integrally with a main body part 106 of the powder delivery nozzle
- Figures 10 to 12 of the drawings show streamlines for gases moving away from a region heated by the laser beam, namely, from the intersection point 32 previously described, for the powder delivery assembly shown in Figures 1 to 6, and in Figures 7 to 9, respectively.
- the gasses are able to flow smoothly around and over the various parts of the assembly 12 without creating eddies or turbulent flow.
- this shows the heat profile of the powder delivery assembly 12 caused by radiated heat from the melt pool 32.
- the powder delivery assembly 12 of the invention does not have surfaces that are normal/perpendicular to the intersection point 32, radiated heat is more effective reflected off the surfaces of the powder delivery assembly and away from the melt pool 32.
- the improved thermal and powder delivery characteristics of the invention mean that much lower laser powers can be used to obtain the same or similar effects to known powder delivery nozzles. Also, as the powder delivery assembly of the invention is inherently less susceptible to being heated convectively and/or radiatively, the cooling requirements for the invention are much reduced, compared with known powder delivery assemblies.
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Plasma & Fusion (AREA)
- Manufacturing & Machinery (AREA)
- Powder Metallurgy (AREA)
- Nozzles (AREA)
Abstract
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1911499.0A GB2573715A (en) | 2017-01-19 | 2018-01-19 | Powder delivery assembly |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1700957.2 | 2017-01-19 | ||
GBGB1700957.2A GB201700957D0 (en) | 2017-01-19 | 2017-01-19 | Powder delivery nozzle |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2018134605A1 true WO2018134605A1 (fr) | 2018-07-26 |
Family
ID=58462912
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/GB2018/050154 WO2018134605A1 (fr) | 2017-01-19 | 2018-01-19 | Ensemble de distribution de poudre |
Country Status (2)
Country | Link |
---|---|
GB (2) | GB201700957D0 (fr) |
WO (1) | WO2018134605A1 (fr) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN109605749A (zh) * | 2018-12-21 | 2019-04-12 | 陕西恒通智能机器有限公司 | 一种大型3d打印喷嘴装置 |
WO2020136268A1 (fr) * | 2018-12-28 | 2020-07-02 | Fives Machining | Tête optique d'impression 3d par projection de poudre |
CN111872565A (zh) * | 2020-08-19 | 2020-11-03 | 中国人民解放军空军工程大学 | 适用于大型零部件的现场激光冲击水约束层施加装置及施加方法 |
WO2021156317A1 (fr) * | 2020-02-07 | 2021-08-12 | Trumpf Laser- Und Systemtechnik Gmbh | Unité de dépôt de matériau pour rechargement par soudage à la poudre |
CN114393828A (zh) * | 2022-01-14 | 2022-04-26 | 中南大学 | 一种3d打印用喷头结构 |
EP3903989A4 (fr) * | 2019-06-11 | 2022-04-27 | Mitsubishi Heavy Industries Machine Tool Co., Ltd. | Dispositif et procédé de stratification tridimensionnelle |
KR102626330B1 (ko) * | 2023-02-15 | 2024-01-17 | 곽송희 | 동축 노즐과 탈축 노즐이 일체로 구비된 일체형 레이저 가공 장치 및 그 제어 방법 |
CN111441045B (zh) * | 2020-05-28 | 2024-03-22 | 西安建筑科技大学 | 一种电子束沉积喷头及方法 |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6046426A (en) * | 1996-07-08 | 2000-04-04 | Sandia Corporation | Method and system for producing complex-shape objects |
WO2000066895A2 (fr) * | 1999-04-29 | 2000-11-09 | The Regents Of The University Of California | Separateur multiple d'alimentation en poudre |
US20060003095A1 (en) * | 1999-07-07 | 2006-01-05 | Optomec Design Company | Greater angle and overhanging materials deposition |
-
2017
- 2017-01-19 GB GBGB1700957.2A patent/GB201700957D0/en not_active Ceased
-
2018
- 2018-01-19 GB GB1911499.0A patent/GB2573715A/en not_active Withdrawn
- 2018-01-19 WO PCT/GB2018/050154 patent/WO2018134605A1/fr active Application Filing
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6046426A (en) * | 1996-07-08 | 2000-04-04 | Sandia Corporation | Method and system for producing complex-shape objects |
WO2000066895A2 (fr) * | 1999-04-29 | 2000-11-09 | The Regents Of The University Of California | Separateur multiple d'alimentation en poudre |
US20060003095A1 (en) * | 1999-07-07 | 2006-01-05 | Optomec Design Company | Greater angle and overhanging materials deposition |
Cited By (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN109605749A (zh) * | 2018-12-21 | 2019-04-12 | 陕西恒通智能机器有限公司 | 一种大型3d打印喷嘴装置 |
WO2020136268A1 (fr) * | 2018-12-28 | 2020-07-02 | Fives Machining | Tête optique d'impression 3d par projection de poudre |
FR3091195A1 (fr) * | 2018-12-28 | 2020-07-03 | Fives Machining | Tete d’impression 3d par projection de poudre |
EP3903989A4 (fr) * | 2019-06-11 | 2022-04-27 | Mitsubishi Heavy Industries Machine Tool Co., Ltd. | Dispositif et procédé de stratification tridimensionnelle |
WO2021156317A1 (fr) * | 2020-02-07 | 2021-08-12 | Trumpf Laser- Und Systemtechnik Gmbh | Unité de dépôt de matériau pour rechargement par soudage à la poudre |
CN111441045B (zh) * | 2020-05-28 | 2024-03-22 | 西安建筑科技大学 | 一种电子束沉积喷头及方法 |
CN111872565A (zh) * | 2020-08-19 | 2020-11-03 | 中国人民解放军空军工程大学 | 适用于大型零部件的现场激光冲击水约束层施加装置及施加方法 |
CN111872565B (zh) * | 2020-08-19 | 2022-05-17 | 中国人民解放军空军工程大学 | 适用于大型零部件的现场激光冲击水约束层施加装置及施加方法 |
CN114393828A (zh) * | 2022-01-14 | 2022-04-26 | 中南大学 | 一种3d打印用喷头结构 |
CN114393828B (zh) * | 2022-01-14 | 2022-11-11 | 中南大学 | 一种3d打印用喷头结构 |
KR102626330B1 (ko) * | 2023-02-15 | 2024-01-17 | 곽송희 | 동축 노즐과 탈축 노즐이 일체로 구비된 일체형 레이저 가공 장치 및 그 제어 방법 |
Also Published As
Publication number | Publication date |
---|---|
GB201911499D0 (en) | 2019-09-25 |
GB201700957D0 (en) | 2017-03-08 |
GB2573715A (en) | 2019-11-13 |
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