# US 11,440,100 B2 · Apparatus and method for additive manufacturing by ultra-high-speed laser cladding

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- Number: US 11,440,100 B2
- Document ID: US11440100B2
- Status: Granted
- Kind: B2
- Application number: 17/298,601
- Filed: 2020-07-07
- Published: 2022-06-30
- Granted: 2022-09-13
- Earliest claimed: 2020-06-17
- Assignees: Jiangsu University
- Applicants: Jiangsu University
- Inventors: Lan Chen; Xudong Ren; Yuzhou Sun; Xinzhou Zhang; Zhaopeng Tong; Wangfan Zhou
- Web page: https://patentgrep.com/patent/US11440100B2

## CPC

- B22F 12/224: {for motion along a direction within the plane of a layer}
- B23K 26/03: Observing, e.g. monitoring, the workpiece
- B22F 10/25: Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 10/364: for post-heating, e.g. remelting
- B22F 10/38: to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
- B22F 10/50: Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
- B22F 10/85: for controlling or regulating additive manufacturing processes
- B22F 12/226: {for rotary motion}
- B22F 12/37: Rotatable
- B22F 12/41: characterised by the type, e.g. laser or electron beam
- B22F 12/90: Means for process control, e.g. cameras or sensors
- B23K 26/032: {using optical means}
- B23K 26/034: {Observing the temperature of the workpiece}
- B23K 26/0823: {Devices involving rotation of the workpiece}
- B23K 26/144: the fluid stream containing particles, e.g. powder
- B23K 26/342: Build-up welding
- B23K 26/60: Preliminary treatment
- B23K 26/702: {Auxiliary equipment}
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 40/00: Auxiliary operations or equipment, e.g. for material handling
- B33Y 40/10: Pre-treatment
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- G01B 11/06: for measuring thickness {; e.g. of sheet material (thickness measurement by thermal means G01B21/085)}
- G01C 3/02: Details
- B22F 10/36: of energy beam parameters
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- Y02P 10/25: Process efficiency
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- 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
- B33Y: 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
- G01B: MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01C: MEASURING DISTANCES, LEVELS OR BEARINGS; SURVEYING; NAVIGATION; GYROSCOPIC INSTRUMENTS; PHOTOGRAMMETRY OR VIDEOGRAMMETRY (measuring liquid level G01F; radio navigation, determining distance or velocity by use of propagation effects, e.g. Doppler effects, propagation time, of radio waves, analogous arrangements using other waves G01S)
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

The present invention relates to an apparatus and method for additive manufacturing by ultra-high-speed laser cladding. The apparatus includes a laser generator, a beam expander, and a reflector. A light exit path of the reflector is arranged facing a cladding nozzle. The cladding nozzle is connected to a powder pool through a hose and a pump in succession. A matrix is arranged below the cladding nozzle. The matrix is located on a rotary platform. A main stepping motor is fixedly mounted below the rotary platform. The main stepping motor is fixed on a lifting platform. A laser rangefinder is arranged above the matrix. During the laser cladding-based additive manufacturing process, the ultrasonic vibration device, the infrared camera, the high-speed camera, the laser rangefinder, and the radiological inspection system are turned on to monitor the laser cladding process in real time.

## Claims

### Claim 1

An apparatus for additive manufacturing by ultra-high-speed laser cladding, comprising a laser generator, a beam expander, and a reflector, wherein a light exit path of the reflector is arranged facing a cladding nozzle, the cladding nozzle is connected to a powder pool through a hose and a pump in succession, a matrix is arranged below the cladding nozzle, the matrix is located on a rotary platform, a main stepping motor is fixedly mounted below the rotary platform, the main stepping motor is fixed on a lifting platform, and a laser rangefinder is arranged above the matrix,
wherein the cladding nozzle is fixed on an electric slider A, the cladding nozzle is configured to move on an electric slide rail A by the electric slider A, the electric slide rail A is fixed on an electric slider B, the electric slide rail A is configured to move on an electric slide rail B by the electric slider B, the reflector is connected to an electric slider C by a rotary shaft, and the reflector is configured to move on an electric slide rail C by the electric slider C,
wherein a plurality of ultrasonic vibration platforms is arranged on the rotary platform, the matrix is placed on each of the ultrasonic vibration platforms, and each of the ultrasonic vibration platforms is configured to rotate on the rotary platform through an auxiliary stepping motor.

### Claim 2 (depends on 1)

The apparatus for additive manufacturing by ultra-high-speed laser cladding according to claim 1, wherein an infrared camera and a high-speed camera are arranged above the matrix.

### Claim 3 (depends on 2)

The apparatus for additive manufacturing by ultra-high-speed laser cladding according to claim 2, wherein a radiological inspection system is arranged above the matrix.

### Claim 4 (depends on 3)

The apparatus for additive manufacturing by ultra-high-speed laser cladding according to claim 3, wherein the laser generator, the pump, the lifting platform, the main stepping motor, the auxiliary stepping motor, the ultrasonic vibration platforms, the electric slider A, the electric slider B, the electric slider C, the radiological inspection system, the infrared camera, the high-speed camera, and the laser rangefinder are connected to a control system by signal cables.

### Claim 5 (depends on 1)

The apparatus for additive manufacturing by ultra-high-speed laser cladding according to claim 1, wherein the laser generator is a fiber laser generator with the following settings: wavelength: 1080 nm, rated output power: 4000 W, focal length: 280 mm, power adjustable range: 5-100%; fiber output interface: QCS; focal spot intensity distribution: plateau; laser operation mode: CW; output power stability: <3%; laser-dedicated cloud service remote diagnosis system; 15 m transmission fiber.

### Claim 6 (depends on 4)

A method for additive manufacturing using the apparatus for additive manufacturing by ultra-high-speed laser cladding of claim 4, comprising the following steps:
Step S1: grinding, cleaning, blowing dry and preheating the matrix;
Step S2: fixing the matrix to the ultrasonic vibration platform, and controlling the lifting platform to be fine-tuned so that there is a suitable distance H between the matrix and the nozzle; controlling the electric slider B to drive the nozzle to move to an innermost side of the rotary platform; measuring a distance D1 to the matrix by the laser rangefinder;
Step S3: driving the rotary platform by the main stepping motor to start to rotate, to cause the matrix to undergo a displacement with respect to the cladding nozzle;
Step S4: controlling the pump to start operating, to spray a powder from the powder pool to the surface of the matrix through the cladding nozzle; focusing a laser outputted from the laser generator onto the surface of the matrix through the nozzle, to melt the powder sprayed on the surface of the matrix; controlling the ultrasonic vibration platform to start to vibrate and rotate, so that the powder sprayed on the surface of the matrix is completely melted, to reduce formation of pores;
Step S5: capturing temperature of the molten pool using the infrared camera, capturing a width of the molten pool using the high-speed camera, feeding back the temperature and the width to the control system for determining whether the powder has been sufficiently melted, and then dynamically controlling a rotating speed of the rotary platform to achieve a suitable laser energy density; dynamically controlling a vibration frequency of the ultrasonic vibration platform to sufficiently melt the powder;
Step S6: measuring a distance D2 to a cladding layer using the laser rangefinder, calculating a thickness of the cladding layer by subtracting D1 from D2, determining whether the thickness of the cladding layer meets an expected requirement, and then dynamically controlling a powder feeding rate to ensure an even thickness of the cladding layer;
Step S7: after the rotary platform completes one revolution, stopping the output of the laser, and stopping the feeding of the powder from the pump; driving the cladding nozzle by the electric slider B to move a distance X toward an outer side of the rotary platform;
Step S8: repeating the Steps S4, S5, S6, and S7 until additive manufacturing of one layer has been completed;
Step S9: stopping the rotation of the main stepping motor, performing non-contact defect detection for the obtained cladding layer using the radiological inspection system, and recording a position of a defect;
Step S10: controlling the electric slider B to move along the electric slide rail B, to drive the nozzle to move to the innermost side of the rotary platform; lowering the lifting platform by a height H; causing the ultrasonic vibration platform to rotate by an angle α;
Step S11: changing parameters in a process of ultra-high-speed laser cladding-based additive manufacturing of a next layer by the control system according to the position of the defect recorded by the radiological inspection system, so that when the nozzle moves over the defect, the laser power and the powder feeding rate are increased, to repair the defect by remelting; and
Step S12: repeating the Steps S3, S4, S5, S6, S7, S8, S9, S10, and S11 until all additive manufacturing processes have been completed.

### Claim 7 (depends on 6)

The method for additive manufacturing according to claim 6, wherein in the ultra-high-speed laser cladding-based additive manufacturing process, the nozzle moves on the electric slide rail A by the electric slider A to change an angle between an axis of the cladding nozzle and the surface of the matrix, to overcome a centrifugal force generated on the molten powder on the surface of the matrix due to rotation; the reflector is configured to rotate about an axis of rotation and move on the electric slide rail C by the electric slider C to change an angle and position of reflected light so that light is reflected by the reflector to enter the cladding nozzle; and the angle between the axis of the cladding nozzle and the surface of the matrix is determined by a distance from the cladding nozzle to the axis of the rotary platform and the rotating speed of the rotary platform.

### Claim 8 (depends on 6)

The method for additive manufacturing according to claim 6, wherein in the Step S8 and the Step S12, during cladding, the laser generator has: a laser power of 3000-4000 W; a scanning speed of 1-200 m/min; a spot diameter of 1-3 mm; an overlap rate of 0-100%; and a cladding layer thickness of 10-1000 μm.

### Claim 9 (depends on 2)

The apparatus for additive manufacturing by ultra-high-speed laser cladding according to claim 2, wherein the laser generator is a fiber laser generator with the following settings: wavelength: 1080 nm, rated output power: 4000 W, focal length: 280 mm, power adjustable range: 5-100%; fiber output interface: QCS; focal spot intensity distribution: plateau; laser operation mode: CW; output power stability: <3%; laser-dedicated cloud service remote diagnosis system; 15 m transmission fiber.

### Claim 10 (depends on 3)

The apparatus for additive manufacturing by ultra-high-speed laser cladding according to claim 3, wherein the laser generator is a fiber laser generator with the following settings: wavelength: 1080 nm, rated output power: 4000 W, focal length: 280 mm, power adjustable range: 5-100%; fiber output interface: QCS; focal spot intensity distribution: plateau; laser operation mode: CW; output power stability: <3%; laser-dedicated cloud service remote diagnosis system; 15 m transmission fiber.

### Claim 11 (depends on 4)

The apparatus for additive manufacturing by ultra-high-speed laser cladding according to claim 4, wherein the laser generator is a fiber laser generator with the following settings: wavelength: 1080 nm, rated output power: 4000 W, focal length: 280 mm, power adjustable range: 5-100%; fiber output interface: QCS; focal spot intensity distribution: plateau; laser operation mode: CW; output power stability: <3%; laser-dedicated cloud service remote diagnosis system; 15 m transmission fiber.