Hand held powder-fed laser fusion welding torch

• US 6,593,540 B1
• Filed: 02/08/2002
• Issued: 07/15/2003
• Est. Priority Date: 02/08/2002
• Status: Expired due to Term

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Hehmann, William F., Baker, Martin C., Winchester, Gary, Renteria, Federico, Haraz, Richard F., Papotto, Vincent J., Das, Santosh K.
• Primary Examiner(s): Dunn, Tom
• Assistant Examiner(s): JOHNSON, JONATHAN J
• Application Number:
  US10/071,025
• Time in Patent Office: 522 Days
• Field of Search: 219/121.63, 219/121.64, 219/121.65, 219/121.66, 219/121.6, 228/54
• US Class Current: 219/121.63
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 26/0096 Portable laser equipment, e.g. hand-held laser apparatus surgical laser instruments A61B18/20, Dental Lasers A61C1/0046, Hand-held laser dental apparatus for curing resins A61C19/004
• CPC Class Codes: B23K 26/10 using a fixed support , i.e. involving moving the laser beam
• CPC Class Codes: B23K 26/144 the fluid stream containing particles, e.g. powder
• CPC Class Codes: B23K 26/1482 Detachable nozzles, e.g. exchangeable or provided with breakaway lines
• CPC Class Codes: B23K 26/30 of three-dimensional seams
• CPC Class Codes: B23K 26/32 taking account of the properties of the material involved
• CPC Class Codes: B23K 26/34 Laser welding for purposes other than joining
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B23K 35/0222 for use in soldering, brazing B23K35/0205 takes precedence
• CPC Class Codes: B23K 35/0244 Powders, particles or spheres; Preforms made therefrom
• CPC Class Codes: B23K 35/0255 for use in welding B23K35/0205 takes precedence
• CPC Class Codes: B23K 35/38 Selection of media, e.g. special atmospheres for surrounding the working area
• CPC Class Codes: B23P 6/007 using only additive methods, e.g. build-up welding

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.

Claims

1. A hand held powder-fed laser fusion welding torch for treating a workpiece, comprising:

a body;

a nozzle assembly mounted on the body, the nozzle assembly defining a central nozzle aperture through which gas and light, including laser light, may pass; and

wherein the nozzle defines first and second powder flow channels aligned with a working focal point adjacent the central nozzle aperture, whereby fusion powder may be transmitted through the first and second powder flow channels for fusing by laser light transmitted through the central nozzle aperture.

2. A hand held powder-fed laser fusion welding torch for treating a workpiece as set forth in claim 1, further comprising:

a powder feed supply system coupled to the first and second powder flow channels and supplying the first and second powder flow channels with fusion powder.

3. A hand held powder-fed laser fusion welding torch as set forth in claim 1, further comprising:

the first and second powder flow channels being located in opposed positions and tapered.

4. A hand held powder-fed laser fusion welding torch as set forth in claim 1, further comprising:

first and second powder flow tubes respectively inserted into the first and second powder flow channels, the first and second powder flow tubes providing a conduit between a powder flow supply and the first and second powder flow channels.

5. A hand held powder-fed laser fusion welding torch as set forth in claim 1, further comprising:

the nozzle having a hollow cylindrical rear section attached to a hollow frustro-conicular front section;

the front section terminating in a flat toroidal face circumscribing the central nozzle aperture;

the first and second powder flow channels symmetrically emerging from the nozzle face;

entrances to the first and second powder flow channels located in the rear to section and adjacent the front section.

6. A hand held powder-fed laser fusion welding torch as set forth in claim 1, further comprising:

a nozzle gas cover attached to the nozzle;

the nozzle gas cover defining a cover aperture generally coaxial with the nozzle aperture;

the nozzle gas cover defining a gas inlet for introduction of gas, including noble gasses;

the nozzle gas cover generally spaced apart from but in close proximity to the nozzle so as to provide a shroud about the nozzle through which gas may flow before exiting through the cover aperture;

whereby

gas may be controllably introduced between the nozzle and the nozzle gas cover so as to provide a controlled environment through which laser light and fusion powder may pass on to the working focal point.

7. A hand held powder-fed laser fusion welding torch as set forth in claim 1, further comprising:

a handle, the handle being removably coupleable and positionable with respect to the nozzle.

8. A hand held powder-fed laser fusion welding torch as set forth in claim 1, further comprising:

a controller adapted to selectively provide light to the torch;

a proximity sensor coupled to the nozzle, the proximity sensor adapted to a workpiece when the nozzle aperture is adjacent the workpiece, the proximity sensor changing its signal state to the controller to activate the welding torch when the workpiece is in a predetermined position to selectively activate the welding torch when the workpiece is in the predetermined position.

9. A hand held powder-fed laser fusion welding torch as set forth in claim 8, further comprising:

the proximity sensor coupled to the workpiece and establishing a closed electrical circuit when the proximity sensor touches the workpiece, the closed circuit enabling activation of the welding torch and breaking of the closed circuit deactivating the welding torch.

10. A hand held powder-fed laser fusion welding torch as set forth in claim 8, further comprising:

a controller adapted to selectively apply light to the torch;

the proximity sensor comprising a switch that turns on when the workpiece activates the proximity sensor and turns off when the proximity sensor is deactivated, the switch turning on and off the welding torch according to the on and off state of the switch.

11. A hand held powder-fed laser fusion welding torch as set forth in claim 8, wherein the proximity sensor provides feedback regarding nozzle position.

12. A hand held powder-fed laser fusion welding torch as set forth in claim 11, wherein the proximity sensor further comprises:

a proximity sensor selected from the group consisting of contact and non-Patent contact proximity sensors.

13. A hand held powder-fed laser fusion welding torch as set forth in claim 11, wherein the proximity sensor further comprises:

a proximity sensor providing feedback for compensating for variations in a distance between the nozzle and the workpiece such that foci of laser light and powder flow are accommodated according to variations in distance between the nozzle and the workpiece.

14. A hand held powder-fed laser fusion welding torch as set forth in claim 11, wherein the proximity sensor further comprises:

a feedback circuit, said feedback circuit providing feedback to the welder selected from the group consisting of audio feedback and video feedback.

15. A hand held powder-fed laser fusion welding torch, comprising:

a nozzle defining a central nozzle aperture through which light, including laser light, may pass, the nozzle having a hollow cylindrical rear section attached to a hollow frustro-conicular front section, the front section terminating in a flat toroidal face circumscribing the central nozzle aperture;

the nozzle defining first, second, third, and oppositely opposed powder flow channels focused on a working focal point adjacent the central nozzle aperture;

the first, second, third, and fourth powder flow channels being tapered to promote the focused flow of powder to the working focal point;

the first, second, third, and fourth powder flow channels symmetrically emerging from the nozzle face;

entrances to the first, second, third, and fourth powder flow channels located in the rear section and adjacent the front section;

first, second, third, and fourth powder flow tubes respectively inserted into the first, second, third, and fourth powder flow channels, the first, second, third, and fourth powder flow tubes providing a connection and conduit between powder flow supply lines and the first, second, third, and fourth powder flow channels;

a powder feed supply system coupled to the first, second, third, and fourth powder flow channels and supplying the first, second, third, and fourth powder flow channels with fusion powder; and

a proximity sensor coupled to the nozzle, the proximity sensor sensing a workpiece before the central nozzle aperture adjacent the working focal point, the proximity sensor enabling activation of the welding torch when a workpiece is sensed before the central nozzle aperture and disabling activation of the welding torch when a workpiece is not sensed before the central nozzle aperture;

whereby

fusion powder may be transmitted through the first, second, third, and fourth powder flow channels for fusing by laser light transmitted through the central nozzle aperture.

16. A hand held powder-fed laser fusion welding torch as set forth in claim 15, wherein the proximity sensor further comprises:

a nozzle gas cover coupled to the nozzle;

the nozzle gas cover defining a cover aperture generally coaxial with the nozzle aperture;

the nozzle gas cover defining a gas inlet for introduction of gas, including inert gasses; and

the nozzle gas cover generally spaced apart from but in close proximity to the nozzle so as to provide a shroud about the nozzle through which the gas may flow before exiting through the cover aperture;

whereby

gas may be controllably introduced between the nozzle and the nozzle gas cover so as to provide a controlled environment through which laser light and fusion powder may pass on to the working focal point.

17. A hand held powder-fed laser fusion welding torch as set forth in claim 15, further comprising:

the proximity sensor coupled to the workpiece and establishing a closed electrical circuit when the proximity sensor touches the workpiece, the close circuit enabling activation of the welding torch and breaking of the closed circuit deactivating the welding torch.

18. A hand held powder-fed laser fusion welding torch as set forth in claim 15, further comprising:

the proximity sensor comprising a switch that turns on when the workpiece depresses the proximity sensor and turns off when the proximity sensor is extended, the switch turning on and off the welding torch according to the on and off state of the switch.

19. A hand held powder-fed laser fusion welding torch as set forth in claim 15, further comprising:

the proximity sensor being a non-contact proximity sensor.