Handheld stirring friction solid-phase additive manufacturing device and method

Abstract

The invention discloses a handheld stirring friction solid-phase additive manufacturing device which comprises a handheld angle grinder, an adapter, a charging barrel adapter, a static charging barrel and an inverted-cone-shaped rotary stirring head, the adapter is connected to the lower portion of the handheld angle grinder, and the inverted-cone-shaped rotary stirring head is integrally and directly connected with the handheld angle grinder. The charging barrel connecting piece is connected to the connecting piece, the static charging barrel is fixed to the charging barrel adapter, the inverted-cone-shaped rotary stirring head is inserted into the static charging barrel, a plurality of feeding channels are formed in the side edge of the static charging barrel, and a plurality of protruding structures are arranged at the bottom of the static charging barrel. The device is low in cost, small in size and convenient to operate.

Description

Technical Field

[0001] This invention relates to additive manufacturing technology, and more particularly to a handheld stirring friction solid phase additive manufacturing apparatus and method. Background Technology

[0002] In the friction stir additive manufacturing process, the stirring head rotates at high speed and generates heat through friction with the metal material, bringing it to a thermoplastic state. Simultaneously, under axial pressure, interlayer metallurgical bonding and layer-by-layer deposition are achieved. This process maintains the metal in a thermoplastic solid state throughout, effectively avoiding defects such as voids and cracks caused by melting and solidification, while also overcoming the challenge of precisely controlling precipitated phases. Furthermore, due to the intense plastic deformation and dynamic recrystallization during deposition, the resulting deposited layer typically possesses superior mechanical and fatigue properties. Therefore, friction stir solid-state additive manufacturing technology shows broad application prospects in fields requiring high-strength aluminum alloys, such as aerospace and transportation.

[0003] Existing friction stir manufacturing equipment based on wire materials, such as the one described in patent CN120901460A (patent title: A Friction Stir Additive Manufacturing Device for High-Strength Aluminum Alloy Powder-Core Wire), suffers from inherent drawbacks such as large size, complex structure, and insufficient adaptability. This results in cumbersome operation, high energy consumption, and the need for a larger motor due to its large size, severely reducing its convenience. Due to these limitations, this equipment is unsuitable for precision machining and repair of small components.

[0004] Current friction stir additive manufacturing equipment generally suffers from limitations, primarily in its large overall size, complex system structure, and fixed processing location. These factors collectively result in high equipment costs, poor portability, and an inability to achieve convenient, ready-to-use operation, making it unsuitable for the flexible on-site manufacturing and rapid repair of small components. Summary of the Invention

[0005] To address the problems existing in the prior art, the purpose of this invention is to provide a handheld stirring friction solid-phase additive manufacturing device and method that is small in size, low in cost, and easy to operate.

[0006] To achieve the above-mentioned objectives, the present invention provides the following technical solution: A handheld friction stir solid-phase additive manufacturing device includes a handheld angle grinder, an adapter, a barrel adapter, a stationary barrel, and an inverted conical rotary stirring head. The adapter is connected to the bottom of the handheld angle grinder, and the inverted conical rotary stirring head is directly connected to the handheld angle grinder. A barrel adapter is connected to the adapter, and the stationary barrel is fixed to the barrel adapter. The inverted conical rotary stirring head is inserted into the stationary barrel. The stationary barrel has multiple feeding channels on its side and multiple protruding structures arranged at its bottom.

[0007] Furthermore, the inverted conical rotary stirring head rotates under the drive of the handheld angle grinder.

[0008] Furthermore, the inverted conical rotating stirring head is provided with a spiral structure.

[0009] Furthermore, the interior of the stationary material cylinder is a conical channel, which is coaxially and closely matched with the shape of the inverted conical rotating stirring head.

[0010] Furthermore, the gap between the inverted conical rotating stirring head and the stationary material cylinder can be changed by adjusting the vertical position of the inverted conical rotating stirring head.

[0011] Furthermore, the handheld angle grinder has multiple threaded holes inside, the adapter has a through hole at the corresponding position on the outer ring, and the barrel adapter also has a countersunk hole at the corresponding position on the outer ring. The screw passes through the countersunk hole and the through hole on the outer ring of the barrel adapter in sequence from bottom to top, and is screwed into the threaded hole inside the handheld angle grinder, thereby fixing the barrel adapter, the adapter, and the handheld angle grinder together.

[0012] Furthermore, the inner ring of the material cylinder adapter is provided with multiple threaded holes, and the outer ring of the stationary material cylinder is provided with through holes at corresponding positions. Screws are screwed through the through holes of the stationary material cylinder into the threaded holes of the inner ring of the material cylinder adapter, thereby fixing the stationary material cylinder onto the material cylinder adapter.

[0013] Furthermore, the handheld angle grinder is a handheld angle grinder with adjustable speed and all components that can be quickly disassembled and conveniently maintained.

[0014] Furthermore, the feed channels are evenly distributed.

[0015] A handheld friction stir solid-phase additive manufacturing method, the method being based on the aforementioned apparatus, specifically comprising: 1) Adjust the speed of the handheld angle grinder 1 to a suitable range within the adjustable speed range of 300~20000rpm, according to the material properties required for different printing tasks; 2) Place the device above the desired printing area and press down until the protruding structure fits tightly against the desired printing area to achieve device positioning and support; 3) Feed the filament or granular material into the stationary cylinder at a uniform speed through the feeding channel until it contacts the conical rotating mixing head, and then stop feeding; 4) Start the handheld angle grinder to rotate at high speed, drive the conical rotating stirring head to rotate, and start to rub against the wire or granular material that has entered the stationary material cylinder, and restart the feeding at the same time; 5) After the filament or granular material reaches a plastic state due to frictional heat, it is continuously conveyed to the bottom of the stationary barrel under the axial pressure of the conical rotating tool. 6) The extruded plastic material fills the gap between the protruding structure at the bottom of the stationary barrel and the area to be printed, forming a deposition layer of a specific height; 7) Under the constraint of the protruding structure, the extruded plastic material forms a deposition layer of a specific width, and then the device moves along the predetermined printing direction to achieve continuous printing.

[0016] Compared with the prior art, the beneficial effects of this invention are: 1. By integrating the inverted conical rotating stirring head with the handheld angle grinder, the length of the entire transmission system is shortened, the structure is more compact, the inherent drawbacks of using couplings are eliminated, and more efficient transmission efficiency and more precise control performance are achieved, while reducing equipment costs.

[0017] 2. The inverted conical design of the stirring head increases the contact area with the feed surface, improves the efficiency of frictional heat generation, and thus improves the overall printing efficiency.

[0018] 3. The spiral structure of the inverted conical rotary mixing head generates downward extrusion force during rotation, continuously pushing the plasticized material to the bottom of the stationary barrel. Simultaneously, the spiral structure effectively guides the material to form an orderly macroscopic flow trajectory.

[0019] 4. By adopting a split modular design, the barrel adapter and the stationary barrel are designed as independent components, which gives the device excellent scalability and replaceability, and simplifies the maintenance process while effectively controlling costs. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the device of the present invention; Figure 2 This is a schematic diagram of the adapter of the device of the present invention; Figure 3 This is a schematic diagram of the feed cylinder adapter of the device of the present invention; Figure 4 This is a schematic cross-sectional view of the inverted conical rotating stirring head of the device of the present invention; Figure 5 This is a schematic cross-sectional view of the stationary feed cylinder of the device of the present invention; Figure 6 This is a diagram of the deposition process of the device of the present invention. Detailed Implementation

[0021] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0022] Example 1 This invention provides a handheld friction stir solid-phase additive manufacturing apparatus, such as... Figure 1-6 As shown, the device includes a handheld angle grinder 1, an adapter 2, a material cylinder adapter 3, a stationary material cylinder 4, and an inverted conical rotary stirring head 7. The adapter 2 is connected to the bottom of the handheld angle grinder 1. The inverted conical rotary stirring head 7 rotates under the drive of the handheld angle grinder 1. The material cylinder adapter 3 is connected to the adapter 2. The stationary material cylinder 4 is fixed to the material cylinder adapter 3. The inverted conical rotary stirring head 7 is inserted into the stationary material cylinder 4. The stationary material cylinder 4 has multiple feeding channels 5 on its side and multiple protruding structures 6 arranged at the bottom of the stationary material cylinder 4 for hand pressure support and flow of deposited material.

[0023] Among them, the handheld angle grinder 1 is a commonly used type on the market. Its main function is to drive the inverted conical rotating stirring head 7 to rotate. Its speed is adjustable, with a maximum speed of 20,000 rpm. All parts can be quickly disassembled and conveniently maintained.

[0024] The inverted conical rotary mixing head 7 and the handheld angle grinder 1 are integrated into one structure, which improves transmission efficiency while ensuring overall structural rigidity. The inverted conical rotary mixing head 7 can generate heat through friction and continuously push thermoplastic filaments or granular materials into the additive manufacturing area. The inverted conical rotary mixing head 7 is equipped with a spiral structure, which increases the contact friction area with the feed. The spiral structure generates downward extrusion force through rotation, and the guiding effect of the spiral structure causes the material to form an orderly spiral flow.

[0025] The handheld angle grinder 1 has multiple threaded holes inside. The adapter 2 has a through hole at a corresponding position on its outer ring. The barrel adapter 3 also has a countersunk hole at a corresponding position on its outer ring. During assembly, screws are passed from bottom to top through the countersunk hole on the outer ring of the barrel adapter 3 and the through hole on the outer ring of the adapter 2, and then screwed into the threaded holes inside the handheld angle grinder 1, thus fixing the barrel adapter 3, adapter 2, and handheld angle grinder 1 together. The barrel adapter 3 has multiple threaded holes on its inner ring, and the stationary barrel 4 has a through hole at a corresponding position on its outer ring. During assembly, screws are passed through the through hole of the stationary barrel 4 and screwed into the threaded holes on the inner ring of the barrel adapter 3, thus fixing the stationary barrel 4 onto the barrel adapter 3.

[0026] The interior of the stationary cylinder 4 is a conical channel that fits snugly against the shape of the inverted conical rotary agitator 7. The gap between the inverted conical rotary agitator 7 and the stationary cylinder 4 can be adjusted by changing the vertical position of the inverted conical rotary agitator 7 to accommodate filaments or granular materials of different sizes. Multiple feeding channels 5 are evenly distributed on the side of the stationary cylinder 4. The filaments or granular materials enter the conical channel inside the stationary cylinder 4 through the feeding channels 5 and are transformed into a thermoplastic state under the rotational friction of the conical rotary agitator 7. Multiple raised structures 6 are provided at the bottom of the stationary cylinder 4. These raised structures 6 provide sufficient space for the extrusion process of thermoplastic materials, ensuring smooth and stable discharge, while also providing positioning and support for the device.

[0027] Example 2 This invention provides a handheld friction stir solid-phase additive manufacturing method, the method being based on the aforementioned apparatus, and specifically comprising: 1) Adjust the speed of the handheld angle grinder 1 to a suitable range within the adjustable speed range of 300~20000rpm, according to the material properties required for different printing tasks; 2) Place the device above the desired printing area and press down until the protruding structure 6 fits tightly against the desired printing area to achieve device positioning and support; 3) Feed the filament or granular material into the stationary cylinder 4 at a uniform speed through the feed channel 5 until it contacts the conical rotating stirring head 7, and then stop feeding; 4) Start the handheld angle grinder 1 to rotate at high speed, drive the conical rotating stirring head 7 to rotate, and start to rub against the wire or granular material that has entered the stationary material cylinder 4, and restart the feeding at the same time; 5) After the filament or granular material reaches a plastic state due to frictional heat, it is continuously conveyed to the bottom of the stationary cylinder 4 under the axial pressure of the conical rotating tool 7. 6) The extruded plastic material fills the gap between the protruding structure 6 at the bottom of the stationary barrel 4 and the area to be printed, forming a deposition layer of a specific height; 7) Under the constraint of the protruding structure 6, the extruded plastic material forms a deposition layer of a specific width, and then the device moves along the predetermined printing direction to achieve continuous printing.

[0028] This invention represents a highly cost-effective, limited modification to existing handheld angle grinders. It employs an integrated direct-connection structure between the conical rotating stirring head and the angle grinder, significantly improving transmission efficiency and drastically reducing equipment space, resulting in a more compact and rigid device. The conical rotating stirring head integrates a spiral structure, combining heat generation with the orderly flow of materials, ensuring stable and efficient manufacturing processes. This invention achieves a comprehensive improvement in structural simplicity, ease of operation, and process integration at extremely low modification costs, providing a practical and low-barrier equipment foundation for the widespread adoption of this technology.

[0029] It should be understood that the embodiments and descriptions above are only the principles, main features and advantages of the present invention. Various changes and modifications can be made to the present invention without departing from the spirit and scope of the invention, and all such changes and modifications fall within the protection scope of the present invention.

Claims

1. A handheld friction stir solid-phase additive manufacturing device, comprising a handheld angle grinder (1), a connector (2), a barrel connector (3), a stationary barrel (4), and an inverted conical rotary stirring head (7). The connector (2) is connected below the handheld angle grinder (1), the inverted conical rotary stirring head (7) is directly connected to the handheld angle grinder (1), the barrel connector (3) is connected to the connector (2), the stationary barrel (4) is fixed on the barrel connector (3), the inverted conical rotary stirring head (7) is inserted into the stationary barrel (4), the stationary barrel (4) has multiple feeding channels (5) on its side, and multiple protruding structures (6) are arranged at the bottom of the stationary barrel (4).

2. The handheld friction stir solid-phase additive manufacturing apparatus according to claim 1, characterized in that: The inverted conical rotary stirring head (7) rotates under the drive of the handheld angle grinder (1).

3. The handheld stirring friction solid-phase additive manufacturing apparatus according to claim 1, characterized in that: The inverted conical rotating stirring head (7) is equipped with a spiral structure.

4. The handheld friction stir solid-phase additive manufacturing apparatus according to claim 1, characterized in that: The interior of the stationary material cylinder (4) is a conical channel, which is coaxially and tightly fitted with the inverted conical rotating stirring head (7).

5. The handheld stirring friction solid-phase additive manufacturing apparatus according to claim 4, characterized in that: The gap between the inverted conical rotary stirring head (7) and the stationary material cylinder (4) is changed by adjusting the vertical position of the inverted conical rotary stirring head (7).

6. The handheld stirring friction solid-phase additive manufacturing apparatus according to claim 1, characterized in that: The handheld angle grinder (1) has multiple threaded holes inside. The adapter (2) has a through hole at the corresponding position on the outer ring. The barrel adapter (3) also has a countersunk hole at the corresponding position on the outer ring. The screw passes through the countersunk hole on the outer ring of the barrel adapter (3) and the through hole on the outer ring of the adapter (2) from bottom to top, and is screwed into the threaded hole inside the handheld angle grinder (1), thereby fixing the barrel adapter (3), the adapter (2), and the handheld angle grinder (1) together.

7. The handheld friction stir solid-phase additive manufacturing apparatus according to claim 1, characterized in that: The inner ring of the barrel adapter (3) has multiple threaded holes, and the outer ring of the stationary barrel (4) has through holes at corresponding positions. The screw passes through the through hole of the stationary barrel (4) and is screwed into the threaded hole of the inner ring of the barrel adapter (3), thereby fixing the stationary barrel (4) on the barrel adapter (3).

8. The handheld stirring friction solid-phase additive manufacturing apparatus according to claim 1, characterized in that: The handheld angle grinder (1) is a handheld angle grinder with adjustable speed and all parts can be quickly disassembled and conveniently maintained.

9. The handheld stirring friction solid-phase additive manufacturing apparatus according to claim 1, characterized in that: The feed channels (5) are evenly distributed.

10. A handheld friction stir solid-phase additive manufacturing method, characterized in that, The method is based on the apparatus of claim 1, and the method specifically includes: 1) Adjust the speed of the handheld angle grinder (1) to a suitable range within the adjustable speed range of 300~20000rpm according to the material properties required for different printing tasks; 2) Place the device above the desired printing area and press down until the protruding structure (6) fits tightly against the desired printing area to achieve the positioning and support of the device; 3) Feed the filament or granular material into the stationary cylinder (4) at a uniform speed through the feeding channel (5) until it contacts the conical rotating stirring head (7), and then stop feeding; 4) Start the handheld angle grinder (1) to rotate at high speed, drive the conical rotating stirring head (7) to rotate, and start to rub against the wire or granular material that has entered the stationary material cylinder (4), and restart the feeding at the same time; 5) After the filament or granular material reaches a plastic state due to frictional heat, it is continuously conveyed to the bottom of the stationary cylinder (4) under the axial pressure of the conical rotating tool (7); 6) The extruded plastic material fills the gap between the protruding structure (6) at the bottom of the stationary barrel (4) and the area to be printed, forming a deposition layer of a specific height; 7) Under the constraint of the protruding structure (6), the extruded plastic material forms a deposition layer of a specific width, and then the device moves along the predetermined printing direction to achieve continuous printing.

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