Laser metal deposition head
Aspects of the present disclosure relate to improved laser metal deposition heads. Various embodiments may include a main body, a nozzle seat, a powder flow guide, an inner nozzle, an outer nozzle, and a coolant sleeve. In some embodiments, powder inlets in the main body are angled relative to a primary axis of the laser metal deposition head. In some embodiments, the nozzle seat includes a plurality of powder distribution channels that are also angled relative to the primary axis of the laser metal deposition head.
1. A laser metal deposition assembly, comprising:
a main body, comprising:
a plurality of powder inlets, each inlet disposed at a first angle relative to a primary axis of the laser metal deposition assembly;
a coolant inlet;
a coolant outlet;
a shield gas inlet; and
a clamp;
a nozzle seat, comprising:
a threaded outer portion configured for receiving an outer nozzle disposed on a first side of the nozzle seat;
a threaded inner portion configured for receiving an inner nozzle disposed on the first side of the nozzle seat;
a coolant inlet channel;
a coolant outlet channel;
a shield gas channel;
a plurality of powder distribution channels; and
a clamp retainer, wherein the clamp retainer and the clamp are operable to fix together the main body and the nozzle seat;
an inner nozzle connected to the threaded inner portion of the nozzle seat;
an outer nozzle connected to the outer threaded portion of the nozzle seat, wherein the outer nozzle and inner nozzle form a conical powder outlet channel therebetween;
a powder flow guide disposed within a second side of the nozzle seat, opposite the first side of the nozzle seat; and
a coolant sleeve comprising:
a coolant entry port;
a coolant outlet port; and
an inner surface in contact with an outer surface of the outer nozzle.
2. The laser metal deposition assembly of claim 1 , wherein the powder flow guide comprises a plurality of helical powder flow channels.
3. The laser metal deposition assembly of claim 2 , wherein the plurality of powder distribution channels are disposed at a second angle relative to the primary axis.
4. The laser metal deposition assembly of claim 3 , wherein:
the main body further comprises an auxiliary gas inlet;
the nozzle seat further comprises a first auxiliary gas channel; and
the coolant sleeve further comprises an auxiliary gas port and an auxiliary gas outlet.
5. The laser metal deposition assembly of claim 4 , further comprising an auxiliary gas cap connected to the coolant sleeve.
6. The laser metal deposition assembly of claim 5 , wherein the auxiliary gas cap further comprises an auxiliary gas seal configured to seal the auxiliary gas outlet in the coolant sleeve.
7. The laser metal deposition assembly of claim 4 , further comprising:
an auxiliary gas nozzle fixed to the coolant sleeve,
wherein the auxiliary gas nozzle forms a second auxiliary gas channel between the auxiliary gas nozzle and the outer nozzle.
8. The laser metal deposition assembly of claim 4 , wherein the powder flow guide and the nozzle seat are arranged to form a powder mixing chamber therebetween.
9. The laser metal deposition assembly of claim 2 , wherein:
the main body further comprises a plurality of powder flow channels, and
each of the plurality of helical powder flow channels in the powder flow guide comprises an end aligned with a powder flow channel of the plurality of powder flow channels in the main body.
10. The laser metal deposition assembly of claim 1 , wherein the first angle is in a range of 15-50 degrees.
11. The laser metal deposition assembly of claim 1 , wherein the plurality of powder inlets are positioned within a lateral extent of the main body.
12. The laser metal deposition assembly of claim 1 , wherein the coolant inlet and the coolant outlet are positioned within a lateral extent of the main body.
13. The laser metal deposition assembly of claim 1 , wherein the shield gas inlet is positioned within a lateral extent of the main body.
14. The laser metal deposition assembly of claim 1 , wherein the first angle is an acute angle with respect to the primary axis.
15. The laser metal deposition assembly of claim 1 , wherein the plurality of powder inlets comprises four powder inlets.
16. The laser metal deposition assembly of claim 1 , wherein the inner nozzle and the outer nozzle comprise a copper-based alloy.
17. The laser metal deposition assembly of claim 1 , wherein the inner nozzle and the outer nozzle comprise an aluminum-based alloy.
18. The laser metal deposition assembly of claim 1 , further comprising:
an extension tube connected to the main body; and
an axial hard stop attached to the extension tube.
19. The laser metal deposition assembly of claim 18 , further comprising: an axial adjustment clamp configured to connect the extension tube to a laser metal deposition assembly positioning system.
20. The laser metal deposition assembly of claim 19 , wherein the laser metal deposition assembly positioning system comprises an X-Y adjustment stage connected to the extension tube.