U.S. patent application number 10/789854 was filed with the patent office on 2004-09-02 for hand held powder-fed laser fusion welding torch.
Invention is credited to Baker, Martin C., Das, Santosh K., Haraz, Richard F., Hehmann, William F., Papotto, Vincent J., Renteria, Federico, Winchester, Gary.
Application Number | 20040169021 10/789854 |
Document ID | / |
Family ID | 22098805 |
Filed Date | 2004-09-02 |
United States Patent
Application |
20040169021 |
Kind Code |
A1 |
Baker, Martin C. ; et
al. |
September 2, 2004 |
Hand held powder-fed laser fusion welding torch
Abstract
A novel and inventive hand held powder-fed laser fusion welding
torch providing manual flexibility for laser welding with
powder-fed material. The hand held laser includes a body, handle,
and nozzle assembly. The nozzle may be shrouded by a cover that is
slightly spaced apart from the nozzle. The gap between the two may
provide space through which inert gas may flow. Laser light from a
remote source shines through the nozzle's central aperture. The
nozzle aperture may be circumscribed by powder channel outlets
aligned upon a working focal point coincident with the laser beam
to treat a workpiece. A proximity sensor may enable selective
welding torch operation according to the presence of a
workpiece.
Inventors: |
Baker, Martin C.; (Budd
Lake, NJ) ; Das, Santosh K.; (Randolph, NJ) ;
Haraz, Richard F.; (Alpharetta, GA) ; Hehmann,
William F.; (Greer, SC) ; Papotto, Vincent J.;
(Winder, GA) ; Renteria, Federico; (Greenville,
SC) ; Winchester, Gary; (Duluth, GA) |
Correspondence
Address: |
HONEYWELL INTERNATIONAL INC.
101 COLUMBIA ROAD
P O BOX 2245
MORRISTOWN
NJ
07962-2245
US
|
Family ID: |
22098805 |
Appl. No.: |
10/789854 |
Filed: |
February 26, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10789854 |
Feb 26, 2004 |
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10071025 |
Feb 8, 2002 |
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6593540 |
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10789854 |
Feb 26, 2004 |
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10460008 |
Jun 12, 2003 |
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Current U.S.
Class: |
219/121.63 ;
219/121.84 |
Current CPC
Class: |
B23K 26/144 20151001;
B23K 26/1482 20130101; B23K 26/342 20151001; B23K 2103/50 20180801;
B23K 35/0255 20130101; B23K 26/32 20130101; B23K 26/0096 20130101;
B23K 26/10 20130101; B23K 35/0244 20130101; B23K 26/30 20130101;
B23P 6/007 20130101; B23K 26/34 20130101; B23K 35/38 20130101; B23K
35/0222 20130101 |
Class at
Publication: |
219/121.63 ;
219/121.84 |
International
Class: |
B23K 026/20; B23K
026/14 |
Claims
What is claimed is:
1. A hand-held laser fusion welding torch system, comprising: a
body having a first end and a second end, the body first end
adapted to couple to a laser beam delivery system; a handle coupled
to the body and dimensioned to be grasped by a hand; a nozzle
coupled to the body second end, the nozzle having an aperture
through which a laser beam from the laser beam delivery system may
pass; and an independent off-axis filler media feed assembly that
provides for independent manipulation and control of the laser beam
and metal powder.
2. The torch system of claim 1, wherein the independent off-axis
filler media feed assembly is operable independent of the laser
beam.
3. The torch system of claim 1, further comprising: a filler media
supply system coupled to the filler media feed assembly and
operable to supply the filler media feed assembly with filler
media.
4. The torch system of claim 1, wherein the independent off-axis
filler media feed assembly further comprises: a gas flow delivery
system operable to transmit gas to an operating site of the
torch.
5. The torch system of claim 1, further comprising: a removable gas
cover adapted to detachably couple to the nozzle, the gas cover
having an aperture through which the laser beam from the laser beam
delivery system may pass when the gas cover is coupled to the
nozzle.
6. A hand-held laser fusion welding torch system, comprising: a
body having a first end and a second end, the body first end
adapted to couple to a laser beam delivery system; a handle coupled
to the body and dimensioned to be grasped by a hand; a nozzle
coupled to the body second end, the nozzle having an aperture about
a first axis through which a laser beam from the laser beam
delivery system may pass; and a filler material nozzle assembly
operable to supply filler media along a direction that is not
aligned with the first axis, wherein the laser beam and the feed
assembly are configured such that each may be manipulated and
controlled independent of one another.
7. The torch system of claim 6, wherein the independent off-axis
filler media feed assembly is operable independent of the laser
beam.
8. The torch system of claim 6, further comprising: a filler media
supply system coupled to the filler media feed assembly and
operable to supply the filler media feed assembly with filler
media.
9. The torch system of claim 6, wherein the independent off-axis
filler media feed assembly further comprises: a gas flow delivery
system operable to transmit gas to an operating site of the
torch.
10. The torch system of claim 6, further comprising: a removable
gas cover adapted to detachably couple to the nozzle, the gas cover
having an aperture through which the laser beam from the laser beam
delivery system may pass when the gas cover is coupled to the
nozzle.
11. A hand-held laser fusion welding torch system, comprising: a
body having a first end and a second end, the body first end
adapted to couple to a laser beam delivery system; a handle coupled
to the body and dimensioned to be grasped by a hand; a nozzle
coupled to the body second end, the nozzle having a nozzle aperture
through which a laser beam from the laser beam delivery system may
pass; and an annular powder delivery orifice arrangement formed in
the nozzle.
12. The torch system of claim 11, wherein: the nozzle includes at
least an end surface and an outer surface; and the annular powder
delivery orifice arrangement comprises: one or more powder delivery
channels extending between an inlet port formed an the nozzle outer
surface and an outlet port formed in the nozzle end surface, and an
annular channel formed in the nozzle end surface and surrounding
the nozzle aperture, the annular channel configured to provide
fluid communication between each of the filler material supply
channel outlet ports.
13. The torch system of claim 11, further comprising: a removable
gas cover adapted to detachably couple to the nozzle, the gas cover
having an aperture through which the laser beam from the laser beam
delivery system may pass when the gas cover is coupled to the
nozzle.
14. The torch system of claim 11, further comprising: a gas flow
delivery system coupled to the removable gas cover.
15. The torch system of claim 11, further comprising: a powder
supply system coupled to the annular powder delivery orifice
arrangement and operable to supply filler media to the filler media
feed assembly.
16. A hand-held laser fusion welding torch system, comprising: a
body having a first end and a second end, the body first end
adapted to couple to a laser beam delivery system; a handle coupled
to the body and dimensioned to be grasped by a hand; a nozzle
having a first end, a second end, and an outer surface, the nozzle
first end coupled to the body second end, the nozzle second end
including an aperture through which a laser beam from the laser
beam delivery system may pass; one or more filler material supply
channels extending between an inlet port formed in the nozzle outer
surface and an outlet port formed in the nozzle second end; and an
annular channel formed in the nozzle second end and surrounding the
nozzle aperture, the annular channel configured to provide fluid
communication between each of the filler material supply channel
outlet ports.
17. The torch system of claim 16, further comprising: a removable
gas cover adapted to detachably couple to the nozzle, the gas cover
having an aperture through which the laser beam from the laser beam
delivery system may pass when the gas cover is coupled to the
nozzle
18. The torch system of claim 17, further comprising: a gas flow
delivery system coupled to the removable gas cover.
19. The torch system of claim 16, further comprising: a powder
supply system coupled to the annular powder delivery orifice
arrangement and operable to supply filler media to the filler media
feed assembly.
20. A method of treating a surface of a workpiece using a hand-held
laser welding torch, the method comprising the steps of: directing
a laser beam through the torch and onto the workpiece surface, to
thereby create a melt pool on the workpiece surface; supplying
filler material from a filler material source to the melt pool; and
manually manipulating the torch and filler material source.
21. The method of claim 20, wherein the torch and filler material
source are manually manipulated independent of one another.
22. The method of claim 20, wherein the torch is manually
manipulated using a handle that is coupled to the torch and
dimensioned to be grasped by a hand.
23. The method of claim 22, wherein: the torch is manually
manipulated by a first hand of a user; and the filler material
source is manually manipulated by a second hand of the user.
24. The method of claim 22, wherein the filler material being
manual manipulated by the second hand of the user is a wire
rod.
25. The method of claim 20, further comprising: controlling
operation of the torch independent of the filler material source.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of application Ser. No.
10/071,025 filed on Feb. 8, 2002, now U.S. Pat. No. 6,593,540 and
application Ser. No. filed on Jun. 12, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to laser fusion welding and more
particularly to a hand held powder-fed laser fusion welding
torch.
[0004] 2. Description of the Related Art
[0005] In general, the surface of a metallic article may be welded
and/or alloyed by the simultaneous and cooperative operation of a
laser beam and an alloy powder stream. To accomplish this, systems
exist that have a laser source and focusing apparatus, with a
powder delivery apparatus provided as part of an integral package.
The laser beam melts a relatively small area at the surface of the
article, and a controlled volume of alloying particles are
delivered into the melt pool via the powder flow stream.
[0006] In laser fusion welding, an article of metal or other
material may have the surface thereof alloyed, or otherwise
treated, by the simultaneous and cooperative operation of a laser
beam with an alloy powder. Typically, the laser beam melts a
relatively small volume of the outer surface of the article and the
powder system delivers a controlled volume of alloying particles
into this molten volume. The alloying particles become dispersed
throughout this volume and therewith alter, complement, or add to
the composition of the outer layer in a controllable way. Removal
of the beam, such as by advancement of the workpiece relative to
the focal point of the beam, causes the molten volume to be rapidly
chilled. The chilling occurs so rapidly that the volume retains the
characteristics of the molten mix.
[0007] As an example, gas turbine engines, such as those utilized
with jet aircraft, are being designed with ever increasing
performance requirements. One element of the engine which has been
receiving attention is the seal created between the outer periphery
of the rapidly rotating blades and the surrounding housing. Another
element subject to attention is the turbine nozzle system in jet
engines.
[0008] The owner of the present invention, Honeywell International,
Inc., often repairs turbine nozzles with a process called JetFix.
The JetFix process uses steps as follows: chemically and
mechanically stripping the outer aluminide coating, welding the
cracks, thermally shocking the welds (to form micro cracks),
fluoride ion cleaning of the cracks, (to remove oxides), applying a
JetFix braze alloy, vacuum furnace brazing, blending brazing,
re-application of aluminide coating, and effective flow area
check.
[0009] Laser powder fusion (LPF) technology has been in use for the
past twelve years and has demonstrated the benefits of small heat
affected zones on turbine airfoils. Some repair facilities, such as
those at Honeywell International Inc., have successfully repaired
over 500,000 airfoils which have subsequently accumulated over 10
million flight hours. However, commercially available LPF machines
are relatively large and usually run along pre-programmed paths for
the repair of a specific part. Thus, one limitation of LPF is the
inability of the user to manipulate the laser torch in a custom
manner during the repair process as the weld occurs. Accordingly,
there is a need for an LPF apparatus that can allow the user to
tailor the weld and welding process to the workpiece as the laser
is being operated. The present invention satisfies this need.
SUMMARY OF THE INVENTION
[0010] The present invention provides a hand-held powder-fed laser
fusion welding torch that allows customized welding by delivery of
laser light onto a stream of welding fusion powder. The ability to
provide such a compact laser welding system increases convenience
and flexibility, enabling the welder to create or repair objects
with greater skill, flexibility, and efficiency.
[0011] Worn or damaged metal parts and assemblies may be repaired
or dimensionally restored through high power laser processing with
a laser source of sufficient intensity to melt the metal surface
while a metallic filler in the form of a powder, wire or rod is
introduced into the melt pool. Metallic precursors in a liquid or
semi-liquid form may also be applied to the surface, allowed to
dry, and then laser processed. In situations where the work surface
is not accessible by conventional workstation type of laser powder
metal fusion equipment, a compact hand-held torch is preferred.
Other cases may involve the repair of parts having irregular and
random cracks or damage not otherwise repairable by robotic or
programmable workstations. In order to perform repairs of this
type, a portable, flexible delivery system is required for both
laser as well as the metal filler. This invention provides for
these needs through the integration of laser beam and metal powder
delivery components into a single compact hand-held unit. The laser
source may be a continuous wave Nd:YAG laser.
[0012] In one embodiment, the hand held laser includes a body and a
nozzle assembly mounted on the body, with the nozzle assembly
defining a central nozzle aperture through which gas and light
including laser light may pass. The nozzle defines first and second
powder flow channels aligned with a working focal point adjacent
the central nozzle aperture. Fusion powder may be transmitted
through the first and second powder flow channels for fusing by
laser light transmitted through the central nozzle aperture.
[0013] In another embodiment, a method is provided to manually
laser powder fusion weld a workpiece in order to effect
construction and/or repair. A hand held powder-fed laser fusion
welding torch is provided that may be manually operated. In such
manual operation, the torch generally enjoys significant degrees of
spatial freedom so that the welder may dispose the torch in a
variety and number of easily-achieved positions. In this way, the
welder may conform his activities to the needs at hand and is
preferably not limited by physical constraints of the laser
torch.
[0014] Other features and advantages of the present invention will
become apparent from the following description of the preferred
embodiment(s), taken in conjunction with the accompanying drawings,
which illustrate, by way of example, the principles of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a right side perspective and exploded view of the
hand held powder-fed laser fusion welding torch assembly according
to the present invention.
[0016] FIG. 2 is a right side cross-sectional view of the hand held
powder-fed laser fusion welding torch of FIG. 1 with an optical
collimator and without the nozzle gas cover.
[0017] FIG. 3 is a right side top and partial cross-sectional view
of the hand held powder-fed laser fusion welding torch of FIG. 1
taken along line 3-3 of FIG. 8.
[0018] FIG. 4 is a right side perspective view of the hand held
powder-fed laser fusion welding torch of FIG. 1 shown as
assembled.
[0019] FIG. 5 is a status/control diagram for the proximity sensor
system.
[0020] FIG. 6 is a right side plan view of the hand held powder-fed
laser fusion welding torch of FIG. 1.
[0021] FIG. 7 is a right side cross-sectional view of the hand held
powder-fed laser fusion welding torch of FIG. 1 taken along line
7-7 of FIG. 6.
[0022] FIG. 8 is a rear plan view of the hand held powder-fed laser
fusion welding torch of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0023] The detailed description set forth below in connection with
the appended drawings is intended as a description of
presently-preferred embodiments of the invention and is not
intended to represent the only forms in which the present invention
may be constructed and/or utilized. The description sets forth the
functions and the sequence of steps for constructing and operating
the invention in connection with the illustrated embodiments.
However, it is to be understood that the same or equivalent
functions and sequences may be accomplished by different
embodiments that are also intended to be encompassed within the
spirit and scope of the invention.
[0024] An alternative and less costly or intrusive process uses a
hand-held laser powder fusion (LPF) torch could repair the turbine
nozzle cracks by local removal of the coating and crack, laser
powder fusion welding, blending and local touch up of the aluminide
coating. The advantages of LPF welding are the low heat input and
resultant heat affected zone which allows welding on turbine
nozzles where previously it was not permitted.
[0025] Worn or damaged metal parts and assemblies may be repaired
or dimensionally restored through high power laser processing with
a laser source of sufficient intensity to melt the metal surface
while a metallic filler in the form of a powder, wire or rod is
introduced into the melt pool. Metallic precursors in a liquid or
semi-liquid form may also be applied to the surface, allowed to
dry, and then laser processed. In situations where the work surface
is not accessible by conventional workstation type of laser powder
metal fusion equipment, a compact hand-held torch is preferred.
Other cases may involve the repair of parts having irregular and
random cracks or damage not otherwise repairable by robotic or
programmable workstations. In order to perform repairs of this
type, a portable, flexible delivery system is required for both
laser as well as the metal filler. This invention provides for
these needs through the integration of laser beam and metal powder
delivery components into a single compact hand-held unit.
Currently, the preferred laser source is a continuous wave Nd:YAG
laser, of medium to high power (e.g., 600-1000 watts), capable of
melting a variety of metals when focused to a spot at the work
surface. In a YAG (Nd:YAG) laser, the amplifying medium is a rod of
yttrium aluminum garnet (YAG) containing ions of the lanthanide
metal neodymium (Nd). Other laser and/or powder feed sources may be
used, as required for particular applications.
[0026] The Nd:YAG laser is used, because:
[0027] 1) The one point zero six micrometer (1.06 .mu.m)
fundamental characteristic wavelength of Nd:YAG lasers is readily
transmitted through flexible silica fiber optic cables;
[0028] 2) The beam spatial characteristics are favorable for
focusing by simple lenses to produce spot sizes on the order of one
millimeter (1 mm) diameter with sufficient power density and
uniformity required to melt metal alloys commonly used in jet
engine applications; and
[0029] 3) The Nd:YAG laser fundamental wavelength is readily
absorbed by the host metal, enabling melting of the metal at lower
laser power settings.
[0030] A fiber optic delivery system permits the laser source to be
located remotely from the hand-held laser welding torch, as
required for hand manipulation.
[0031] The laser torch is comprised of an optical system to focus
the laser beam onto the workpiece, and an integral metal powder
delivery nozzle to deposit metal alloy powder into the metal melt
pool produced by the focused laser radiation. The torch assembly is
optically coupled to the laser source through the flexible fiber
optic light cable. Laser energy emitted by the source is
transmitted through the fiber cable to collimating and focusing
optics contained within the torch housing. The focal spot size is
selected to produce the desired melting of the base material at the
lowest possible laser output power. Melt pool diameter, depth of
penetration, heat affected zone (HAZ) dimensions and weld rate are
closely related to the laser focal spot diameter and total laser
output power. Good results have been achieved with one millimeter
(1 mm) diameter spot sizes with six hundred watts (600 W) of laser
output power. Variations in the base metal characteristics and
desired weld rate may require different spot size and laser power
settings. The spot size and working focal distance are adjusted by
choosing different combinations of collimating and focusing lenses.
The torch assembly can be disassembled in sections to facilitate
lens changes. Laser power is adjusted by varying the power output
setting of the laser source.
[0032] Metal powder is introduced into the weld zone through one or
more nozzles contained within or attached to the laser torch. In
one embodiment, the powder nozzles are coaxial with the optical
beam path. This arrangement is more compact and provides better
access to the workpiece than an offset nozzle design. Greater
flexibility in manipulating the torch is also provided by the
coaxial design. A separate, hand-held off-axis powder delivery
nozzle or nozzles, not attached to the laser torch, may also be
employed. Size, weight, balance and ergonomic features are
incorporated to provide for manual control and manipulation. An
integrated, optionally or selectably removable, handle is included
for enhanced controllability. Removable, interchangeable powder
delivery nozzle tips may accommodate working distances ranging from
one-quarter inch to 3 inches (0.25" to 3").
[0033] Metal powder is metered at a preset flow rate from a remote
feeder/hopper unit to the nozzle assembly via flexible tubing. The
flow can be started and stopped by the operator through a remote
control. One or more integral safety sensor devices may actively
monitor the proximity and orientation of the torch with respect to
the workpiece during operation, thus preventing accidental or
unintentional activation.
[0034] An alternate design may have one or more offset nozzles
attached to the optical focusing assembly. The angle and
relationship of the offset nozzles may be adjusted to provide the
desired placement of metal powder with respect to the laser focal
spot.
[0035] As shown in FIG. 1, the Hand Held Powder-Fed Laser Fusion
Welding Torch 100 has an optional handle 102 to which a body 104 is
attached by a pin, screw, bolt, rivet 106, or other fastener which
passes through the upper portion 108 of the handle 102. The upper
part 108 of the handle 102 is constructed so as to accommodate the
cylindrical configuration of the body 104.
[0036] The body 104 has a lens protector to its rear as described
in more detail below and provides an interchangeable element to
which the nozzle 140 and the beam delivery assembly 130 as well as
the handle 102 may be attached in an interchangeable and convenient
fashion. The upper aperture 120 serves as an inlet through which
bleed gas may flow into the torch 100 and provide a generally inert
environment through which the laser light may travel and in order
to prevent oxidation or other chemical reaction by the laser light.
Additionally, the inert gas may provide an optically predictable
environment through which the laser light may travel. Additionally,
the bleed gas flowing through the upper aperture 120 serves to
prevent and inhibit the entry of a dust or other particulate matter
into the torch 100, particularly the nozzle 140 or other confines
thereof.
[0037] The inert gas may be the same as that described in more
detail below with respect to the nozzle gas cover 170 and generally
encompasses most or all inert gases depending on the applications
to which the torch 100 is put. Such inert gases include helium,
argon, and nitrogen. While the flow rate for the gas flowing
through the nozzle gas cover 170 is on the order of liters per
minute (l/m), the volume of gas flowing through the upper aperture
120 is generally on the order of cubic feet per hour, for example
four cubic feet per hour.
[0038] The handle 102 may be detached from the body 104 in order to
create a handle less torch 100. Under any circumstances, the
operator of the torch must normally use welding gloves or the like
in order to protect his or her hand from ejecta and other material
from the welding site. This ejecta from the welding site is one of
the motivations for the bleed gas flowing through the upper
aperture 120. The bleed gas generally inhibits or prevents the
entry of such ejector back into the torch 100.
[0039] The lower body aperture 122 serves to accommodate the pin or
screw 106, which passes through both the handle 102 and the body
104 in order to attach the body 104 to the handle 102.
[0040] The body 104 has threaded rear 124 and front 126 flanges.
The flange may be threaded for attachment. The rear flange allows
for more secure fixation of the beam delivery assembly 130, which
is shown in cross-sectional detail in FIG. 2. The front flange 126
serves to allow better fixed engagement between the body 104 and
the nozzle 140. The adapter body 104 may have other means by which
it can be attached to the different elements of the torch.
[0041] The size and the shape or the length and diameter of the
adapter body 104, may be sized and/or dimensioned according to the
optical or other characteristics desired in the laser torch 100. If
additional length is needed to accommodate the nozzle 140 or other
structure, the adapter body 104 may be lengthened in order to
accommodate a more distant focal length, for example. Additionally,
the diameter of the adapter body 104 may also be adjusted according
to operating characteristics of the torch 100.
[0042] Furthermore, in an alternative embodiment, the torch 100 may
be constructed in a combined fashion so that all components are in
a single integrated unit. However, this static configuration does
not lend itself to adaptability that may be necessary for different
operations or tasks. Consequently, it is seen as being more
advantageous to provide a component-element structure to the laser
torch 100 so that different operating elements may be dismantled or
disconnected from the others in order to provide easier
maintenance, interchangeability, and adjustability. Generally, with
the optical characteristics, the gas flow characteristics, and the
powder flow characteristics, it is not possible to provide
immediate selectable adjustment for these different facets or
operations. Consequently, separate parts must generally be
independently machined in order to provide the structure or
architecture necessary for providing different operating
characteristics. This includes, for example, the diameter of the
adapter body 104 or the angle at which the powder flows into and
through the nozzle 140.
[0043] The nozzle 140 is generally hollow in its interior mediating
the wide opening at its rear 142 to the narrow front opening 144.
The rear portion of the nozzle 140 is generally cylindrical in
nature, while the front portion is generally frustro-conicular with
a flat front face 146.
[0044] The face 146 of the nozzle 140 is perforated by four powder
flow apertures 148. The powder flow apertures 148 travel backwards
through the body of the nozzle 140 until exiting out the
cylindrical rear portion at rear powder flow apertures 150. As
shown in FIG. 3, the powder flow channel 152 intermediating the
distance between the rear 150 and front 148 powder flow openings is
initially cylindrical and then tapers to mediate the narrowing
diameter between that of the wider rear portion of the channel 152
to the narrow front diameter until the gas channel exits out
through the front powder flow aperture 148 and the face 146.
[0045] Each powder flow channel has inserted into its rear portion
through the rear powder flow aperture 150 a powder flow tube 160
that may be made of copper. The powder flow tubes 160 are
introduced into the powder flow channel 152 through the rear powder
flow apertures 150 in order to provide means of connection for
powder flow lines (not shown) that supply fusion powder to the
welding torch 100 via the powder's forced exit out of the front
apertures 148. The powder flow tubes 160 converge to a powder feed
focal point which allows the converging powder flow streams to mix,
preferably outside the nozzle gas cover 170.
[0046] Also shown in the nozzle 140 is one of two connection holes
166 that allow a pin, rivet, screw or button to secure the nozzle
gas cover 170 to the nozzle 140.
[0047] The nozzle gas cover 170 is generally frustro-conicular in
shape having a cylindrical rear margin 172 that is dominated by the
front frustro-conicular section 174. The front section is truncated
and has a central front aperture 176 surrounded by a flat toroidal
section 178 of the interior. The interior of the nozzle gas cover
170 is generally hollow in order to accommodate the front
frustro-conicular section 184 of the nozzle 140.
[0048] Along the rear cylindrical margin 172 are intruding
indentations 180, which serve to accommodate the protruding rear
ends of the powder flow tubes 160 as they project out from the
powder flow channels 152.
[0049] Generally, there is a snug fit between the margin 172 of the
nozzle gas cover 170 and the area adjacent the rear powder channel
apertures 150 in the area just before the front tapered
frustro-conicular portion 184 of the nozzle 140, where the
transition occurs between the cylindrical section and the tapered
section. This helps to provide a rear seal between the nozzle 140
and the nozzle gas cover 170.
[0050] The nozzle 140 and the nozzle gas cover 170 are slightly
offset and spaced apart to allow gas flow between the exterior of
the front section 184 of the nozzle 140 and the interior of the
front frustro-conicular section 174 of the nozzle gas cover 170. As
shown in FIG. 3, the front aperture 176 of the nozzle gas cover 170
is also spaced apart from the nozzle face 146 in order to provide a
plenum area 186 into which gas may be introduced as described in
more detail below.
[0051] The nozzle gas cover 170 has a gas aperture 190 into which
fits a male-to-female right angle pipe adapter 192. A barb-to-pipe
conduit 194 fits into the female section of the male-to-female
adapter 192 which in turn fits into the gas aperture 190 at the
male end 196 of the adapter 192.
[0052] Left or right fasteners such as pins, screws, bolts or
rivets 198 fit into apertures 200 oppositely opposed on the rear
cylindrical margin 172 and pass into the attachment holes 166 in
the nozzle 140 to attach the nozzle gas cover 170 to the nozzle
140.
[0053] The gas cover 170 and accompanying inert gas structures may
be omitted when the torch 100 is used in an inert environment such
as a welding box, glove box or the like. Additionally,
circumstances where a relatively clean vacuum is available (as in
orbit) may allow the omission of the gas cover 170. Under such
circumstances, the sensor probe 220, if any, should be attached to
the nozzle 140 or other torch structure.
[0054] Additionally, a power connector 210 is attached to the
nozzle gas cover 170 by one of the pins 198. As shown in FIG. 1,
the pin or screw 198 attaching the power connector 210 to the gas
nozzle cover 170 is the left pin or screw 198. The power connector
210 has attached to it a power connector clamp 212, which is held
in place by a screw or bolt 214. The screw 214 additionally holds
in place a proximity switch probe 220, which serves to detect the
presence of a welding object or workpiece in front of the operating
front apertures 144, 176 of the nozzle 140 and nozzle gas cover
170, respectively.
[0055] The proximity probe 220 may be spring biased so that the
extending proximity switch 222 is biased forwardly outwardly from
the proximity holder sleeve 224. The probe 220 is held in
connection to the power connector 210 by the power connector clamp
212 and the connector screw or bolt 214. The workpiece or object
will overcome the spring biasing of the proximity switch forcing it
to travel into the proximity holder sleeve 224 and thus activating
or enabling activation of a power connection for the laser welding
torch 100. The entirety of the welding torch 100 is shown assembled
in FIG. 4.
[0056] FIG. 2 shows the laser torch 100 with the attached optical
beam delivery assembly 130. The optical beam delivery assembly 130
serves to take incoming laser light 250 and focus it immediately in
front of the front aperture 176 of the nozzle gas cover 170. The
optical beam delivery assembly 130 is generally made of optically
inert material so that it will not be affected by laser light or
the like. The optical beam delivery assembly 130 receives the laser
light 250 and initially passes the light through a first
collimator. The optical beam delivery assembly 130 has a first
focusing lens or collimator 252, which may be a 60 mm collimator.
The first collimator 252 generally takes the incoming laser light
and refracts it so that it travels parallel to the interior and
generally cylindrical inner surface of the optical collimator 130.
The parallel-traveling light then shines upon a focal lens 254,
which may be a 90 mm focal lens. The focal lens 254 then focuses
the parallel-traveling light to a point immediately in front of the
front aperture 176 of the nozzle gas cover 170.
[0057] The first collimator 252 and the focal lens 254 are spaced
inside the optical collimator 130 so as to effectively provide
light gathering and focusing qualities with the first collimator
252 generally spaced away from the incoming laser light 250, at a
distance approximately equal to the focal length of the first
collimator lens 252. The focal lens 254 is then located near the
end of the optical beam delivery assembly 130 opposite that of the
incoming laser light 250. As the focal lens 254 is protected by a
lens protector 256, it is spaced apart from the light-exiting end
258 of the optical collimator 130.
[0058] Note should be taken that the beam delivery assembly 130
with its optimal collimating and focusing properties can serve to
focus the focal point of the laser light at, beyond, or before the
focal point of the powder flow and that these two focal points may
be disposed selectively with respect to the end of the nozzle 140.
Under certain circumstances, it may be more advantageous to provide
different focal points for the laser light and the powder flow.
Generally, these focal points would be collinear with the major
axis of the laser torch 100. However, the present invention could
provide alternative embodiments where such focal points are not
collinear.
[0059] In the most preferred embodiment, no dispersion or
absorption of the incoming laser light 250 occurs throughout the
optical collimator 130 or the welding torch 100 in order to provide
higher efficiency and so that as much as the incoming laser light
250 is focused upon the working focal point 270. Minimal dispersion
of the laser light is desired most as the most energy generated and
imparted to the laser light is then delivered to the welding
site.
[0060] Preferably, only the incoming fusion powder traveling
through the powder flow tubes 160 and the powder flow channels 152
obstructs or occludes the focused laser light 250 upon exiting the
nozzle. The powder flow tubes 160 and powder flow channels 152
share the same nominal working focal point 270 as the laser light
250. The exact location of the laser light and powder flow focal
points can be adjusted independently in order to optimize the laser
and powder interaction characteristics. The energy of the laser
light is then focused upon the fusion powder and whatever working
surface is set before the open front end 176 and the nozzle gas
cover 170.
[0061] To provide for such independent adjustment of the laser and
powder, the body 104 of the torch 100 may be interchangeable and
provide a selectable variety of diameters and lengths as
appropriate or useful for the welding activities, as indicated
above.
[0062] Additionally, in order to provide for higher transmission of
the laser light, anti reflection coating may be present on the
lenses through which the laser light 250 passes. Furthermore, the
focusing lens 254 may be subject to possible threaded adjustment so
that the focal point of the laser light may be adjusted manually
and spontaneously by the welder. Such threaded adjustment may take
the form of an adjustment screw that moves a carriage on which the
focusing lens 254 translates.
[0063] In operation, laser light is supplied as by optical fiber or
the like to the light receiving end 262 of the optical beam
delivery assembly 130. The laser light is then focused
simultaneously with the fusion powder on the working focal point
270. The energy of the laser light is sufficient to melt the fusion
powder and, preferably, also at least some surface portion of the
workpiece object to be welded and adjoined with the laser liquefied
fusion powder. It is then possible to perform welds or other
construction operations on metals or other surfaces susceptible to
laser welding.
[0064] While the laser welding torch 100 can be used without fusion
powder, the conjunctive use of the fusion powder with the laser
light 250 provides means by which repairs, seams and other
constructive welding activities may be performed on metal objects
or objects of other laser-susceptible materials.
[0065] In operation, the barb-to-pipe conduit 194 snugly and by
means of friction fit receives an outlet connected to a supply of
inert gas, such as the noble gas argon. Argon gas is then used to
flood the plenum 186 as the front nozzle portion 184 is slightly
offset from the interior of the nozzle gas cover 170 in order to
provide a frustro-conicular pathway for the inert gas to flow into
the area between the nozzle 140 and the nozzle gas cover 170 and
into the plenum 186.
[0066] Inert gases are used in order to prevent the unintentional
combination of molecules in the bleed and nozzle flow gas with the
welding site. Such inert gases are known in the art and may be
similar to those used in TIG (tungsten inert gas) welding (also
known as GTAW or gas tungsten arc welding). Inert gases generally
have the quality of not combining with other materials or
molecules. Helium is one predominately-used inert gas and is a
noble gas, as is argon. However, nitrogen may also be used as inert
gas under some circumstances.
[0067] Additionally, if the welding site is to be doped or
intentionally contaminated with substances beyond the substrate or
the feed powder, the gas transport system may serve to deliver some
doping compounds or molecules into the welding site. Some
experimentation may be necessary with this embodiment, however,
controlled oxidation, such as by the introduction of oxygen into
the inert gas, may be desirable under such circumstances. Other
gases could also be introduced into the inert gas flow in order to
provide such intentional alteration of the chemical structure at
the weld site.
[0068] By the application of non-reactive inert gas, the powder and
working surface subject to the incoming laser light 250 is kept
from oxidizing or otherwise combining with anything but the
surrounding material. Free oxygen or other gasses in the
immediately adjacent environment close to the working focal point
270 are displaced by the inert gas. This allows a greater amount of
control with respect to the welding of the workpiece object and/or
the fusion powder. It also diminishes combustion, oxidation, and
the likelihood thereof and provides for a better welding operation
as only the materials sought to be welded are made liquid or soft
by the energetic incoming laser light 250.
[0069] By providing a hand-held powder-fed laser fusion welding
torch as set forth herein, laser welding operations now become much
easier for the aerospace mechanic or other metal worker.
Additionally, with the availability of intense laser light via
fiber optic cables as well as fusion powder in connection with the
powder feed tubes 160, the welding torch provides more useful means
by which welding operations may be achieved.
[0070] Similar to that as shown in FIG. 5, the proximity probe 220
may operate in conjunction with the laser source 280 in order to
provide automatic switching operation according to the proximity of
the workpiece 282. In one embodiment, wiring is connected to the
power connector 210, and the proximity switch 222 then enables
activation of the laser source 280 once sufficiently depressed into
the proximity holder 224.
[0071] Generally, the proximity switch 222 only enables activation
and does not serve to actually activate the torch 100 unless it is
the last element in the activation mechanism. The activation of the
proximity switch 222 is a necessary, but not a sufficient,
condition for the operation of the torch 100. The activation of the
proximity switch 222 is necessary because it must be activated in
order in order for the torch 100 to operate. However, the proximity
switch 222 is not a sufficient condition as it alone is not able to
activate the torch 100. A hand held trigger or the like (not shown)
may also be used in conjunction with torch 100 in order to provide
additional control for the welder over the torch 100.
[0072] Alternatively, and as shown in FIG. 5, if the workpiece is
electrically conductive, an electrical return path 284 may be
established via an interlock control circuit 286, which controls
electrical supply via an electrical supply path 288. With the
closure of the electrical circuit via the safety probe 220,
electrical return path 284, interlock control circuit 286, and
electrical supply path 288, the interlock control circuit 286 will
detect that the laser torch or laser torch 100 is in sufficient
proximity to the workpiece 282 such that the laser torch 100 should
be activated by the activation of the laser source 280. The
interlock control circuit 286 upon detecting a closed circuit path
may enable activation of the laser source 280 so that laser light
sufficient to perform welding operations may be transmitted via the
laser emission path 288 to the laser torch 100. Furthermore, the
interlock control circuit 286 may also control a powder source 290
in the form of a powder feed assembly or the like.
[0073] The powder feed assembly 290 may be similar to that as is
known in the art. Powder for the melt is transmitted as by pumping
or the like to the nozzle 140 for transmission through the powder
flow channels 152. A source or reservoir for the alloy powder may
be kept at a distance from the laser torch 100 and transmitted to
the nozzle 140 by pressurized lines or the like.
[0074] Additionally, other types of sensors may be used in order to
gauge the proximity of the torch 100, and the focal point, from the
welding substrate. Such sensors included non contact sensors that
may use induction, capacitance, or optical characteristics in order
to gauge the distance of the torch 100 from the welding substrate.
The torch 100 is contemplating as using laser light having a
wavelength of approximately 1.06 micrometers delivering energy
sufficient to perform the welding activity set forth herein. The
use of metal powder may subject a capacitive non-contact sensor to
certain difficulties. Additionally, the heat and infrared energy
generated by the torch may also provide optical difficulties for an
optical non-contact sensor. However, certain other qualities may be
used in order to provide non-contact sensors and/or these
difficulties may be overcome due to the characteristics of the
particular non-contact sensor. Additionally, other sensors
developed in the future may be applied to the torch 100 and may
provide advantageous proximity sensing so that they may be easily
or advantageously incorporated into the torch 100.
[0075] Although not shown in FIG. 5, the interlock control circuit
may also control the supply of fusion powder as well as the flow of
inert gas to the laser torch 100.
[0076] The proximity probe or sensor 220 enhances operational
safety through target discrimination and pointing constraints. It
provides process control by defining or maintaining the correct
working distance from the nozzle gas cover aperture 176 to the
workpiece 282. The proximity sensor 220 may either provide physical
limits of working distance, or in the case of a closed loop control
system, provide distance feedback for an automatic working distance
compensation apparatus. Additional feedback may be provided by the
proximity sensor regarding relative positioning between the weld
site and the torch 100. The proximity sensor 220 may provide audio
and/or video feedback to the welder regarding such relative
positioning. Moreover, the proximity sensor may provide sufficient
feedback to allow the automatic adjustment of the laser light 250
and the powder flow.
[0077] The hand held laser welding torch 100 may include the
integrated safety/proximity sensor 220 which has an electrically
isolated contact probe 220 with a spring-loaded telescoping probe
tip (available as an off the shelf component) 222 attached to the
output end of the laser torch via the nozzle gas cover 170. The
sensor 220 may be gold plated for better conductance. This probe,
along with the metallic surface of the workpiece 282, forms an
electrical path for a laser process shutter control circuit 280. In
order to enable emission of the laser output, the safety sensor 220
must be both physically and electrically connected to the desired
workpiece 282. In so doing, the workpiece itself must be isolated
from ground and insulated from adjacent metal components. The
relationship of the position of the safety probe 220 while in
contact with the workpiece 282 defines the direction of laser
emission and ensures that the correct target has been selected. An
electrical return path 284 must be provided from the workpiece 282
to the laser process shutter control circuit 280. This is
established through an electrical wire connection from the
workpiece to the process control system. An alligator clip or
equivalent clamp provides a suitable means for connecting to the
workpiece.
[0078] Target discrimination is achieved by virtue of the required
electrical contact as illustrated in FIG. 5. Laser emission is
prevented unless direct electrical contact between the safety
sensor probe 220 and the workpiece 282 has been established.
[0079] Process control of the torch-to-workpiece working distance
is also provided in this apparatus. The proximity sensor probe 220
includes a spring loaded, telescoping tip 222. The range of
movement of this tip defines the working distance as the operator
manually follows the contours of the part. Alternate working
distances and ranges of height tolerance are provided by a
selection of interchangeable probe tips. Since the tip is easily
replaced, new tips can be installed as needed due to normal wear
and tear. Additionally, advances in laser-focusing and powder-feed
technologies may allow the adjustment of the working focal point
270 according to the working distance detected by the tip 222.
[0080] In an alternate approach, a point contact linear variable
displacement transducer (LVDT) may be used in place of the basic
spring-loaded probe described above. The LVDT probe provides a
source of electrical feedback proportional to its displacement.
This signal may be used to actively control the laser and powder
metal deposition systems to maintain a predetermined distance
between the torch 100 and the workpiece 282 through a closed-loop
feedback system interfaced with motorized lens and powder nozzle
position actuators.
[0081] In another approach, one or more non-contact sensors may be
attached to the welding torch 100 to provide safety discrimination
and position sensing. The advantage of this approach lies in the
high degree of flexibility and dexterity provided by a non-contact
system. Access to a wider range of workpiece component shapes and
configurations are possible compared with the point contact
sensor.
[0082] Candidate sensors may be based on, but not necessarily
limited to optical, capacitive, inductive or video technology.
Combinations of more than one type of sensor may be necessary in
order to provide the necessary degree of part discrimination and
displacement resolution. The non-contact sensor technologies may be
used with either manual operator or automatic closed loop control
systems to maintain part distance requirements.
[0083] The hand held powder-fed laser fusion welding torch makes
laser welding a manual process and no programming is necessary. It
makes it easier to maneuver the laser output wand/torch into hard
to reach places such as nozzles with curvatures. This feature
allows for three-dimensional (3D) welding in random locations. Most
existing laser welding systems are two dimensional (2D) and are
limited due to automatic programming requirements with minimal x-y
movements such that they cannot handle much variation between
parts.
[0084] In the hand held powder-fed laser fusion welding torch, the
laser beam and powder are focused outside of the nozzle. This helps
to prevent the nozzle exit from clogging.
[0085] Shielding inert gas is used to protect the powder and
substrate from contamination (i.e., oxidation) by removing oxygen
and other reactive gases from the weld area. A lightweight design
makes the laser torch ergonomically correct, easy to use and
maintain. YAG laser use with fiber optic cable creates the
flexibility provided by using the hand held torch while delivering
the laser beam to the weld area.
[0086] Proximity sensors allow welding to start at the focal point.
The sensor is also used as a safety feature, to allow the laser
beam start only when its focal point is close to the desired weld
area. Inert carrier gas is used to deliver the powder to the focal
point. This is to prevent any oxidation of the weld and powder. All
details, or elements, of the nozzle assembly can be easily
replaced. All components are easily screwed together.
[0087] In wielding or using the laser torch 100, a method is
provided to manually laser powder fusion weld a workpiece in order
to effect construction and/or repair. A hand held powder-fed laser
fusion welding torch is provided that may be manually operated. In
such manual operation, the torch generally enjoys significant
degrees of spatial freedom so that the welder may dispose the torch
in a variety and number of easily-achieved positions. In this way,
the welder may conform his activities to the needs at hand and is
preferably not limited by physical constraints of the laser
torch.
[0088] The workpiece 282 may first be prepared as by solvent
cleaning or the like to ensure that the workpiece is clean and
ready for welding. Once prepared, the welding torch 100 is prepared
for use with the source of laser light and source of fusion powder
made ready. Depending on the construction of the welding torch 100,
the proximity sensor 220 may be brought into contact with the
workpiece 282. Once the welder is ready, a trigger (not shown) may
be pressed to activate the welding torch 100 and the welding
process upon the workpiece 282. Laser light and powder flow are
then delivered by the laser torch 100 to the work site and the
welding process is performed upon the workpiece.
[0089] While the present invention has been described with
reference to a preferred embodiment or to particular embodiments,
it will be understood that various changes and additional
variations may be made and equivalents may be substituted for
elements thereof without departing from the scope of the invention
or the inventive concept thereof.
[0090] Particularly, the interchangeable nature of fasteners
demands that the indication of one type of fastener or fastening
herein is contemplated as enabling and disclosing all types of
fasteners or fastenings that may be implemented to achieve all or
part of the functionality of the disclosed type of fastener or
fastening. For example, a bolt, screw, pin, rivet, or dowel may be
interchangeable with one another as well as fastening as by
welding. Likewise, other interchangeable elements, operations, or
functions are contemplated as being similarly disclosed herein when
one or more of such interchangeable or equivalent elements,
operations, or functions are disclosed.
[0091] In addition, many modifications may be made to adapt a
particular situation or material to the teachings of the invention
without departing from the essential scope thereof. Therefore, it
is intended that the invention not be limited to particular
embodiments disclosed herein for carrying it out, but that the
invention includes all embodiments falling within the scope of the
appended claims.
* * * * *