Soft-touch solid-phase addition manufacturing process and system

Abstract

An additive manufacturing system for adding a feed material to a substrate, comprising: a feed material supply system configured to supply the feed material; and an extrusion die system having a rotation drive system configured to rotate an extrusion die member in relative and physical contact with a non-rotating feed material, thereby generating sufficient friction to locally heat and soften the feed material.

Description

Technical Field

[0001] The present disclosure relates to additive manufacturing methods, and more particularly, to an additive manufacturing method for metallic materials using solid-state material processing based on rotary friction extrusion.

Background Art

[0002] This section provides background information related to the present disclosure and does not necessarily constitute prior art. This section also provides a general overview of the present disclosure and does not disclose all of its full scope or all of its features.

[0003] Generally, the present system and process are newly developed additive manufacturing methods for depositing metallic materials using solid-state material processing based on rotary friction extrusion. In some embodiments, the process uses a metallic feed rod (circular, square, or any other shape), a mechanism for pushing the feed rod, a mechanism for preventing rotation of the feed rod, a non-rotating (stationary) guide tube, and a rotary extrusion die profile disposed at the end of the feed rod. The extrusion die / tool generates friction, softens the material, extrudes it, and deposits it (additively layer by layer) onto the substrate material. The extrusion die / tool can be designed as a single component for non-ferrous metals (soft metals) and as a multi-component design for ferrous metal (hard metal) deposition using an additive manufacturing method based on rotary friction extrusion, and vice versa configurations are also possible.

Summary of the Invention

Problems to be Solved by the Invention

[0004] This disclosure provides friction extrusion die / tool ​​designs for the SoftTouch AM (trademark) solid-phase addition manufacturing process for non-ferrous metals (such as aluminum, aluminum alloys, copper, copper alloys, and other metals / alloys) and ferrous metals (such as mild steel, stainless steel, high-entropy alloys, nickel-based alloys, high-temperature alloys, and other metals / alloys). Generally, these tool designs generate rotational friction to soften the feed material and provide an extrusion profile for softening, extrusion, and deposition onto a substrate. The single-part extrusion tool / die designs for non-ferrous materials and the multi-part extrusion tool designs for ferrous materials are provided along with experimental results demonstrating their functionality. [Means for solving the problem]

[0005] Accordingly, according to the principles of the present invention, a SoftTouch additive manufacturing system and method (SoftTouch AM®) is disclosed that enables the deposition of a metallic material using solid-state material processing based on rotary friction extrusion. In some embodiments, an additive manufacturing system for additively manufacturing a feed material on a substrate comprises a feed material supply system configured to supply the feed material, and an extrusion die system having a rotary drive system configured to rotate an extrusion die member in relative and physical contact with the feed material to generate sufficient rotational friction to locally heat the feed material.

[0006] According to one aspect of the present disclosure, an additive manufacturing system for adding a feed material onto a substrate includes a feed material supply system configured to supply the feed material. The rotary extrusion die system includes a drive system configured to rotate an extrusion die member in relative and physical contact with the feed material to generate sufficient friction to locally heat and soften the feed material, the rotary extrusion die member having an extrusion orifice through which the heated and softened feed material is extruded.

[0007] In a further embodiment, the extrusion die member does not come into contact with the feed material in any tangential or circumferential direction, and the feed material does not rotate in any case.

[0008] In a further embodiment, the extrusion die member is positioned at a distance from the substrate.

[0009] In a further embodiment, an extrusion die system having a rotary drive system is configured to rotate the extrusion die member in relative and physical contact with the feed material to generate sufficient friction to locally heat the feed material, plasticize it, and provide a plastically deformable feed material that is extruded and deposited through the extrusion orifice of the extrusion die member.

[0010] In a further embodiment, the extrusion die member comprises an outer surface adjacent to an orifice, the outer surface configured to engage with the extruded and deposited plastically deformable feed material.

[0011] In a further embodiment, the extrusion die member includes an eccentric orifice.

[0012] In a further embodiment, the extrusion die member includes a rectangular slot-shaped orifice.

[0013] In a further embodiment, the extrusion die member includes a bowtie-shaped orifice.

[0014] In a further embodiment, the extrusion die member includes a dogbone-shaped orifice.

[0015] In a further embodiment, the extrusion die member includes a Y-shaped orifice.

[0016] In a further embodiment, the supply material has a square cross-sectional shape.

[0017] In a further embodiment, the supply material has a circular cross-sectional shape.

[0018] According to a further aspect, the extrusion orifice includes a plurality of orifices.

[0019] According to a further aspect, the plurality of orifices are D-shaped.

[0020] According to a further aspect, the plurality of orifices are triangular in shape.

[0021] According to a further aspect, the extrusion die member includes a die retainer having an opening therein and an insert received within the opening, and the extrusion orifice extends through the insert.

[0022] According to a further aspect, the die member includes a plurality of mounting holes therein.

[0023] According to a further aspect, the extrusion die member is connected to the drive system via a heat insulating washer.

[0024] According to a further aspect, the feedstock supply system includes a channel and an end nut removably attached to the distal end of the channel and having a hole through which the feedstock is delivered.

[0025] According to a further aspect, a retainer washer is disposed opposite the end nut.

[0026] According to a further aspect, a burr cutting mechanism is attached to the rotary extrusion die system.

[0027] According to a further aspect, the burr cutting mechanism includes a radial passage.

[0028] According to a further aspect, the rotary extrusion die system includes one of a liquid cooling system or an air cooling system.

[0029] From the description provided herein, further applicable areas will become apparent. The description and specific examples in this summary are for illustrative purposes only and are not intended to limit the scope of the present disclosure.

[0030] The drawings described herein are for illustrative purposes only of selected embodiments and do not show all possible implementations, nor are they intended to limit the scope of the present disclosure.

Brief Description of the Drawings

[0031] [Figure 1] It is a schematic diagram of an additive manufacturing system according to the principles of the present disclosure. [Figure 2] A schematic diagram of an additive manufacturing system according to the principles of the present disclosure is shown, with some parts omitted for clarity. [Figure 3A] A rotary extrusion die according to the principles of the present disclosure is shown. [Figure 3B] A rotary extrusion die according to the principles of the present disclosure is shown. [Figure 3C] A rotary extrusion die according to the principles of the present disclosure is shown. [Figure 4A] An exemplary rotary extrusion die according to the principles of the present disclosure is shown. [Figure 4B] Corresponding rotary friction extrusion deposits disposed on a substrate according to the principles of the present disclosure are shown. [Figure 5A] The die orifice of a rotary extrusion die and the cross-sectional shape of a corresponding feed material are shown. [Figure 5B] The die orifice of a rotary extrusion die and the cross-sectional shape of a corresponding feed material are shown. [Figure 6A] The die orifice of a rotary extrusion die and the cross-sectional shape of a corresponding feed material are shown. [Figure 6B] The die orifice of a rotary extrusion die and the cross-sectional shape of a corresponding feed material are shown. [Figure 7A] The die orifice of a rotary extrusion die and the cross-sectional shape of a corresponding feed material are shown. [Figure 7B]The cross-sectional shape of the die orifice of a rotary extrusion die and the corresponding feed material is shown. [Figure 8A] The cross-sectional shape of the die orifice of a rotary extrusion die and the corresponding feed material is shown. [Figure 8B] The cross-sectional shape of the die orifice of a rotary extrusion die and the corresponding feed material is shown. [Figure 9A] The cross-sectional shape of the die orifice of a rotary extrusion die and the corresponding feed material is shown. [Figure 9B] The cross-sectional shape of the die orifice of a rotary extrusion die and the corresponding feed material is shown. [Figure 10A] The cross-sectional shape of the die orifice of a rotary extrusion die and the corresponding feed material is shown. [Figure 10B] The cross-sectional shape of the die orifice of a rotary extrusion die and the corresponding feed material is shown. [Figure 11A] This shows the die orifice of a rotary extrusion die. [Figure 11B] This shows the die orifice of a rotary extrusion die. [Figure 11C] This shows the die orifice of a rotary extrusion die. [Figure 11D] This shows the die orifice of a rotary extrusion die. [Figure 12A] This shows a rotary extrusion die configuration for multiple components. [Figure 12B] This shows a rotary extrusion die configuration for multiple components. [Figure 13A] This shows a rotary extrusion die configuration for multiple components. [Figure 13B] This shows a rotary extrusion die configuration for multiple components. [Figure 14A] This shows a rotary extrusion die configuration for multiple components. [Figure 14B] This shows a rotary extrusion die configuration for multiple components. [Figure 15A] This shows a rotary extrusion die configuration for multiple components. [Figure 15B] This shows a rotary extrusion die configuration for multiple components. [Figure 15C] This shows a rotary extrusion die configuration for multiple components. [Figure 15D] This shows a rotary extrusion die configuration for multiple components. [Figure 15E] This shows a rotary extrusion die configuration for multiple components. [Figure 16A] This shows a rotary extrusion die configuration for multiple components. [Figure 16B] This shows a rotary extrusion die configuration for multiple components. [Figure 17A] This shows a rotary extrusion die configuration for multiple components. [Figure 17B] This shows a rotary extrusion die configuration for multiple components. [Figure 18A] This shows a rotary extrusion die configuration for multiple components. [Figure 18B] This shows a rotary extrusion die configuration for multiple components. [Figure 19A] This shows a rotary extrusion die configuration for multiple components. [Figure 19B] This shows a rotary extrusion die configuration for multiple components. [Figure 19C] This shows a rotary extrusion die configuration for multiple components. [Figure 19D] This shows a rotary extrusion die configuration for multiple components. [Figure 19E] This shows a rotary extrusion die configuration for multiple components. [Figure 20A] This shows a rotary extrusion die configuration for multiple components. [Figure 20B] This shows a rotary extrusion die configuration for multiple components. [Figure 20C] This shows a rotary extrusion die configuration for multiple components. [Figure 20D] This shows a rotary extrusion die configuration for multiple components. [Figure 21A] This shows a rotary extrusion die configuration for multiple components. [Figure 21B] This shows a rotary extrusion die configuration for multiple components. [Figure 21C] This shows a rotary extrusion die configuration for multiple components. [Figure 21D] This shows a rotary extrusion die configuration for multiple components. [Figure 22A] This shows a rotary extrusion die configuration for multiple components. [Figure 22B]This shows a rotary extrusion die configuration for multiple components. [Figure 22C] This shows a rotary extrusion die configuration for multiple components. [Figure 22D] This shows a rotary extrusion die configuration for multiple components. [Figure 23] The tip edge shape of the rotary extrusion die relating to the principle of this disclosure is shown. [Figure 24A] The structure of the ceramic insulating washer relating to the principle of this disclosure is shown. [Figure 24B] The structure of the ceramic insulating washer relating to the principle of this disclosure is shown. [Figure 24C] The structure of the ceramic insulating washer relating to the principle of this disclosure is shown. [Figure 25] A rotary extrusion die according to a further embodiment is shown. [Figure 26] Figure 25 is a cross-sectional view of the rotary extrusion die shown. [Figure 27A] Figure 25 is a top perspective view of the retainer of the rotary extrusion die shown. [Figure 27B] Figure 25 is a bottom perspective view of the retainer of the rotary extrusion die shown. [Figure 28A] Figure 25 is a top perspective view of the holder for the rotary extrusion die shown. [Figure 28B] Figure 25 is a bottom perspective view of the holder of the rotary extrusion die shown. [Figure 29A] Figure 25 is a top perspective view of the end nut of the rotary extrusion die shown. [Figure 29B] Figure 25 is a bottom perspective view of the end nut of the rotary extrusion die shown. [Figure 30A] Figure 25 is a top perspective view of the die insert of a rotary extrusion die. [Figure 30B] Figure 25 is a bottom perspective view of the die insert of the rotary extrusion die shown. [Figure 31] This is a top view of an extrusion die holder equipped with a two-part insert relating to the principle of this disclosure. [Figure 32]This is a perspective view of a nozzle and die tool set equipped with a burr cutting mechanism. [Figure 33] This is a cross-sectional view of a nozzle and die tool set with burr-cutting features. [Figure 34] Figure 33 is a top perspective view of the nozzle in the embodiment shown. [Figure 35] Figure 33 is a top perspective view of the burr cutting mechanism according to the embodiment. [Figure 36] Figure 33 is a top perspective view of the die holder according to the embodiment. [Figure 37] This is a bottom perspective view of a die tool set equipped with a burr cutting mechanism according to the second embodiment. [Figure 38] Figure 37 is a top perspective view of the die tool set shown. [Figure 39] Figure 37 is a cross-sectional view of the die tool set shown. [Figure 40] Figure 37 is a top perspective view of the retainer of the rotary extrusion die shown. [Figure 41] Figure 37 is a bottom perspective view of the retainer of the rotary extrusion die shown. [Figure 42A] Figure 37 is a top perspective view of the die holder of the rotary extrusion die shown. [Figure 42B] Figure 37 is a bottom perspective view of the die holder of the rotary extrusion die shown. [Figure 43A] Figure 37 is a top perspective view of the die insert of a rotary extrusion die. [Figure 43B] Figure 37 is a bottom perspective view of the die insert of the rotary extrusion die shown. [Figure 44] This is a perspective view of the burr cutting teeth relating to the principle of this disclosure. [Figure 45] This is a schematic diagram of an additive manufacturing system according to the principle of the present disclosure, equipped with a cooling accessory on a rotary extrusion die. [Figure 46] This is a schematic diagram of an additive manufacturing system according to the principle of the present disclosure, in which cooling air (or liquid carbon dioxide, other cooling or phase-change liquids, powders, or gaseous media) is supplied to a rotary extrusion die by a blower. [Figure 47] This is a schematic diagram of an additive manufacturing system according to the principle of the present disclosure, which includes a rotary extrusion die for depositing additive material onto a substrate in a cooling bath. [Figure 48] This is an illustrative graph of process parameters in an additive manufacturing process relating to the principles of this disclosure. [Modes for carrying out the invention]

[0032] Throughout the drawings, corresponding symbols indicate corresponding parts.

[0033] Next, exemplary embodiments will be described in more detail with reference to the attached drawings.

[0034] To make this disclosure sufficient and to fully convey its scope to those skilled in the art, exemplary embodiments are provided. Numerous specific details, such as examples of particular components, apparatus, and methods, are described in order to fully understand the embodiments of this disclosure. It will be apparent to those skilled in the art that specific details are not required, that the exemplary embodiments can be carried out in many different forms, and that none should be construed as limiting the scope of this disclosure. In some exemplary embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

[0035] The terms used herein are intended solely to describe and not limit to specific exemplary embodiments. Where used herein, the singular forms “a,” “an,” and “the” may also be intended to include the plural form unless explicitly indicated otherwise in the context. The terms “comprises,” “comprising,” “including,” and “having” are inclusive and thus prescribe the presence of the described features, components, steps, operations, elements, and / or members, but do not preclude the presence or addition of one or more other features, components, steps, operations, elements, members, and / or groups thereof. The method steps, processes, and operations described herein should not be construed as having to be performed in a specific order described or illustrated unless specifically designated as such. It should also be understood that additional or alternative steps may be used.

[0036] When an element or layer is described as “on top of,” “engaged with,” “connected to,” or “joined with” another element or layer, it may be directly on top of, engaged with, connected to, or joined to the other element or layer, or there may be an intervening element or layer. In contrast, when an element is described as “directly on top of,” “directly engaged with,” “directly connected to,” or “directly joined with” another element or layer, there may be no intervening element or layer. Other words used to describe relationships between elements (e.g., “between…” and “directly between…”, “adjacent” and “directly adjacent”) should be interpreted similarly. As used herein, the term “and / or” includes any combination of one or more of the enumerated items relating to it.

[0037] Terms such as "first," "second," and "third" may be used herein to describe various elements, components, regions, layers, and / or sections, but these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or section from another region, layer, or section. Terms such as "first," "second," and other numerals, when used herein, do not imply order or arrangement unless explicitly indicated by the context. Accordingly, without departing from the disclosure of exemplary embodiments, the first element, component, region, layer, or section described below may be referred to as the second element, component, region, layer, or section.

[0038] For example, spatial relative terms such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” and “upper” can be used herein to facilitate explanations of the relationship between one element or configuration and another, as shown in the figures. Spatial relative terms may be intended to encompass different orientations of the device in use or operation, in addition to the orientation shown in the figures. For example, if the device in the figure is inverted, an element described as “below” or “beneath” of another element or configuration will be oriented “above” of the other element or configuration. Thus, the example of the term “below” can encompass both above and below orientations. The device may also be in other orientations (90-degree rotation or other orientations), and the spatial relative descriptors used herein will be interpreted accordingly.

[0039] The principles of this disclosure provide an additive manufacturing system for adding a feed material onto a substrate or a previous layer, having an advantageous structure and method of use. In some embodiments, the additive manufacturing system comprises a feed material supply system configured to supply a feed material, and an extrusion die system having a rotary drive system configured to rotate an extrusion die member in relative and physical contact with the feed material to generate sufficient friction to locally heat and soften the feed material. In no case does the feed material rotate. The extrusion die member does not contact the feed material on any tangential or circumferential surface of the feed material. The extrusion die member is always positioned away from the substrate. In some embodiments, the extrusion die system having a rotary drive system is configured to rotate the extrusion die member in relative and physical contact with the feed material to generate sufficient friction to locally heat and plasticize the feed material, thereby providing a plastically deformable feed material to be extruded and deposited through an orifice of the extrusion die member. In some embodiments, the extrusion die member has an outer surface adjacent to the orifice, which is configured to engage with or plaster the plastically deformable feed material that is extruded and deposited.

[0040] Referring particularly to Figures 1 and 2, an additive manufacturing system 10 having an advantageous structure and method of use is provided. Also known as SoftTouch AM (trademark name), the additive manufacturing system 10 is an additive manufacturing method designed, configured, and operable to deposit a metallic material onto a substrate 1000 or a previously deposited layer(s) 1002 using rotational friction-based solid-phase material processing. In some embodiments, the additive manufacturing system 10 uses a metallic feed material in the form of a rod 12, and a feed material feeding system 14 (e.g., an extrusion mechanism) is configured to feed the feed material 12, an anti-rotation mechanism 16 engages with the feed material 12 to prevent rotation of the feed material 12, a non-rotating guide tube 18 receives and guides the feed material 12, and a rotary extrusion die 20 is provided at the end of the feed material 12. The rotary extrusion die 20 is rotated at very high speed by a rotating sleeve and drive mechanism 22, generating localized frictional heating in at least the distal portion of the feed material 12, softening the feed material 12 and extruding (additionally depositing layer by layer) a plastically deformable material onto the substrate 1000. In some embodiments, the rotary extrusion die 20 can be a single-piece (i.e., integrated) design for non-ferrous metals (i.e., soft metals) or a multi-piece design for depositing ferrous metals (i.e., hard metals, hard alloys, or hard materials (e.g., nickel alloys, high-entropy alloys, etc.)). In either case, it should be understood that the tool 20 does not come into direct contact with the substrate 1000.

[0041] It should be understood that this disclosure provides extrusion die / tool ​​designs for solid-phase addition manufacturing of non-ferrous metals (e.g., aluminum, aluminum alloys, copper, copper alloys, and other metals / alloys) and ferrous metals (e.g., mild steel, stainless steel, and other metals / alloys). Generally, the tool design provides an extrusion profile for generating friction, then locally heating and softening the feed material, and then depositing the softened feed material 1002 onto a substrate 1000. Similar to known 3D printing techniques, various desired shapes can be formed by stacking multiple deposits 1002 of the softened feed material on top of each other.

[0042] In some embodiments, the feed system 14 includes a piston or forward system configured to propel the feed material 12 forward, driven, or otherwise advance it from a first position or source toward a rotary extrusion die 20. It should be understood that the feed system 14 does not rotate, nor does it impart rotational motion to the feed material 12.

[0043] In some embodiments, the ends of the non-rotating guide tube 18 are configured to further ensure that the feed material 12 does not rotate and remains positionally stable (i.e., does not wobble or exhibit lateral displacement) at the contact surface between the feed material 12 and the rotary extrusion die 20, in order to achieve an efficient plastically deformable state and extrusion. For this purpose, the non-rotating guide tube 18 can be positioned coaxially with the feed material 12. That is, in some embodiments, the non-rotating guide tube 18 comprises a tubular member having an internal volume or channel sized to receive the feed material 12. In some embodiments, a spindle member 22 can be positioned outside the non-rotating guide tube 18 to further support the non-rotating guide tube 18 and / or the rotary extrusion die 20. In some embodiments, the spindle member 22 is driven in a rotational direction about a central axis.

[0044] In some embodiments, the rotary extrusion die 20 is positioned on the distal end of the spindle member 22. The spindle member 22 can be part of any known type of rotary drive system, including but not limited to electric, hydraulic, and pneumatic motors, and may include a gear mechanism to increase the drive ratio of the spindle member 22. In some embodiments, the rotary extrusion die 20 is selectively coupled to the spindle member 22 so as to rotate together with the spindle member 22. As the spindle member 22 and the rotary extrusion die 20 rotate, the rotary extrusion die 20 generates friction, softening the feed material 12, and extruding this softened, plastically deformable material, depositing it onto the substrate 1000 and / or deposit layer 1002. In some embodiments, the rotary extrusion die 20 includes an extrusion opening or die orifice 24 extending through the die face 26. In some embodiments, the die orifice 24 is configured to have a shape and dimensions suitable for generating friction, heating and softening the feed material 12, and then extruding and depositing the plastically deformable feed material. The rotary extrusion die 20 may include a plurality of mounting holes 27 used to attach the rotary extrusion die 20 to the spindle member using a plurality of fasteners (not shown). In Figure 2, the die orifice 24 is shown as a dogbone shape.

[0045] In some embodiments, the inner surface of the die face 26 of the rotary extrusion die 20 is in contact with the distal end of the feed material 12. Therefore, in some embodiments, the die face 26 is made of steel, ceramic material, or high-temperature refractory material so as to withstand the high temperatures generated by friction. In some embodiments, the die surface 26 is made from a steel, ceramic, or high-temperature refractory material that can withstand high temperatures (at least above 600°C) and maintain its strength, such as low-carbon or high-carbon steel, tool steel, high-temperature steel, nickel alloy, silicon carbide (SiC), polycrystalline cubic boron nitride (PCBN), silicon carbide diamond or Versimax (SiC / D), tungsten rhenium (various W-Re such as W-3%Re, W-5%Re, W-25%Re, W-26%Re), tungsten rhenium hafnium carbide (WReHfC), tungsten carbide (WC or W2C), lanthanum-doped tungsten (W-La or W-La2O3), pure tungsten (W), or polycrystalline diamond (PCD). In a single-piece design configuration, the entire extrusion die 20 can be made from steel, ceramic, or high-temperature refractory material as described herein.In a multi-component design configuration, the extrusion die 20 may include a first section made from ceramics or high-temperature refractory materials (alumina, zirconia, silicon carbide (SiC), polycrystalline cubic boron nitride (PCBN), silicon carbide diamond or Versimax (SiC / D), tungsten rhenium (various W-Re such as W-3%Re, W-5%Re, W-25%Re, W-26%Re), tungsten carbide (WC or W2C), lanthanum-doped tungsten (W-La or W-La2O3), pure tungsten (W), polycrystalline diamond (PCD), etc.), and the first section The second section surrounding the cushion provides a locking mechanism and can be made from any hard metal (ferrous or other hard metals, low-carbon or high-carbon steel, hardened steel, tool steel, high-temperature steel, titanium alloy, Ni-based alloy, tungsten or tungsten-based alloy (e.g., tungsten rhenium (various W-Re such as W-3%Re, W-5%Re, W-25%Re, W-26%Re, etc.), tungsten carbide (WC or W2C), lanthanum-doped tungsten (W-La or W-La2O3), or others)) to provide a locking mechanism and to hold the assembly mounted on the spindle 22.

[0046] In some embodiments, as shown in Figures 3A to 23B, the die orifice 24 of the rotary extrusion die 20 can be of any shape that helps to provide the desired friction and / or extrusion profile. In some embodiments, the die orifice 24 is configured according to the type of material of the feed material 12. As shown in Figure 3A, a rotary extrusion die 20a with a circular eccentric orifice 24a is shown. As shown in Figure 3B, a rotary extrusion die 20b with an eccentric elongated slot orifice 24b is shown. As shown in Figure 3C, a rotary extrusion die 20c with an elongated slot orifice 24c at the center is shown.

[0047] As shown in Figure 4A, a rotary extrusion die 20e with a bowtie-shaped orifice 24e is shown. Figure 4B shows the corresponding friction extrusion deposit 1002 placed on the substrate 1000 according to the principle of the present disclosure.

[0048] In some embodiments, the feed material 12 may have a cross-sectional shape that is useful for feeding and / or preventing rotation, etc. In some embodiments, the feed material 12 may be a rod shape having a circular, square, or other cross-sectional shape. Referring to Figures 5A and 5B, a cross-sectional shape 12A of the feed material is shown, which includes a circular profile smaller than the width of the corresponding extruded orifice 24f. In Figures 5A to 10A, the illustrated extruded orifice 24f includes two D-shaped orifices 24f. Each D-shaped orifice 24f may be eccentric. In Figures 5B to 10B, the extruded orifice is an elongated slot 24d in the center. Referring to Figures 6A and 6B, a cross-sectional shape 12B of the feed material is shown, which includes a circular profile approximately equal to the width of the corresponding extruded orifices 24f, 24d. Referring to Figures 7A and 7B, a cross-sectional shape 12C of the feed material is shown, which includes a circular profile larger than the width of the corresponding extruded orifices 24f, 24d. Referring to Figures 8A and 8B, the cross-sectional shape 12D of the supply material is shown, which includes a square profile smaller than the width of the corresponding extruded orifices 24f and 24d. Referring to Figures 9A and 9B, the cross-sectional shape 12E of the supply material is shown, which includes a square profile approximately equal to the width of the corresponding extruded orifices 24f and 24d. Referring to Figures 10A and 10B, the cross-sectional shape 12F of the supply material is shown, which includes a square profile larger than the width of the corresponding extruded orifices 24f and 24d.

[0049] Referring to Figures 11A to 11D, further extrusion orifices 24g to 24j are shown. As shown in Figure 11A, a rotary extrusion die 20g is shown with a Y-shaped central orifice 24g. As shown in Figure 11B, a rotary extrusion die 20h is shown with three triangular orifices 24h extending from the center of the rotary extrusion die 20h. As shown in Figure 11C, a rotary extrusion die 20i is shown with three eccentric elongated slot orifices 24i. As shown in Figure 11D, a rotary extrusion die 20j is shown with three spaced-apart triangular orifices 24j.

[0050] In some embodiments, the rotary extrusion die 20 may have a special feature on the leading edge of the profile of the die orifice 24, although the supply material may be hard steel or a hard alloy, etc. In some embodiments, the leading edge of the die orifice 24 may be made of a special hard material such as PCBN, PCD, or SiC / D in a single-part die design or a multi-part die design. Figures 12A to 23B show a two-part rotary extrusion die 120, which includes a die component 30 and an insert 28 that is received in an opening 32 of the die component 30. The opening 32 may have a square, rectangular, or other polygonal shape. The die component 30 may further include a plurality of mounting holes 27. The insert 28 has a shape complementary to the opening 32. The insert 28 includes a die orifice 24, which may have a variety of shapes disclosed herein.

[0051] In the embodiments shown in Figures 16A to 19E, the insert 28 includes a straight stepped sidewall 50 that is received into an opening 32 having a straight stepped sidewall 52. In the embodiments shown in Figures 20A to 20D, the insert 28 has a combination of a straight sidewall portion 54a and a tapered sidewall portion 54b and is received into an opening having a combination of a straight sidewall portion 56a and a tapered sidewall portion 56b. In the embodiments shown in Figures 21A to 21D, the insert 28 has a combination of a straight sidewall portion 58a, a stepped portion 58b, and a tapered sidewall portion 58c and is received into an opening having a combination of a straight sidewall portion 60a, a stepped sidewall portion 60b, and a tapered sidewall portion 60c. In the embodiments shown in Figures 22A to 22D, the insert 28 includes a tapered sidewall portion 62 and is received into an opening 32 having a tapered sidewall portion 64.

[0052] As shown in Figure 23, the leading edge is shown in dark color with respect to the rotational direction shown in the illustration. In some embodiments, the backing material can be any tungsten-based material or an alloy that can withstand very high temperatures (high-temperature steel, alumina, zirconia, SiC, Ni-based alloy, or any tungsten-based refractory material). In some embodiments, the leading edge of the diodeifice 24 may have a rake angle and / or curved shape to provide a stronger and improved extrusion. In some embodiments, a material is desirable that has much higher hardness than the feed material 12 and can withstand high temperatures without losing strength, such as PCBN, PCD, and SiC / D, but not limited to these. These materials can be formed by sintering or die-casting as internal components or inserts (Figures 12A to 23B) or as integral components. In particular, referring to Figures 12A to 23, the insert 28 can be made of any refractory material (e.g., Ni-based material or tungsten(W)-based material, or other material that can withstand high temperatures without losing strength). The outer component or retainer 30 can be made of any material that can withstand high temperatures without losing strength (e.g., high-temperature steel, Ni-based material, or refractory material).

[0053] In some embodiments, a ceramic washer 70 and / or retainer 30 may be provided, as shown in Figures 24A to 24C. In addition to the die retainer 30 and insert 28, a retainer ring and ceramic washer 70 may be added to the rotary extrusion die 20 assembly in the case of a multi-component design. The retainer ring 30 holds the insert in a designated position and prevents the insert from being pushed upward during material deposition. It can be made of any high-temperature steel, or high-temperature refractory material or alloy. In some embodiments, the ceramic washer 70 prevents access heat from transferring into the spindle and provides insulation. It can be made of any high-temperature ceramic (or refractory ceramic) insulating material.

[0054] Referring to Figures 25 to 30B, an extrusion die assembly 80 is shown, comprising a spindle 82 connected to a retainer washer 84 and a die holder 86 which can be made from a high-temperature material such as tungsten lanthanum (tungsten lanthanide) and / or tungsten rhenium alloy. An end nut 88 includes a hole 88a through which the end nut passes for guiding the feed material to an extrusion die insert 92, which is received at the end of a feed channel 90 and supported by the die holder 86. The end nut 88 may include a male thread 88b that engages with a female thread 90a at the end of the feed channel 90. The end nut may include a tapered open end 88c that tapers distally away from the feed material. The retainer washer 84 may include a conical proximal (upper) surface 84a spaced apart from the feed material. The die holder 86 may include a polygonal recess 86a for mating with the corresponding polygonal flange 92a of the extrusion die insert 92. The end nut 88 and the extrusion die insert 92 can be made of a tungsten-rhenium alloy such as W-Re, W-3Re, W-5Re, W-10Re, W-25Re, W-26Re, or W-ReHfC, and can be used with iron-based and harder metal alloy feedstocks, and can also be made of high-tensile steel or other steels for aluminum or softer metal alloy feedstocks. The distance "D" between the tip of the end nut 88 and the distal end of the conical upper surface 84a of the retainer washer 84 can range from 0 to 1 times the diameter of the feedstock 12. The extrusion die insert 92 can have any of the die orifice shapes 24 as disclosed herein. The end nut 88, retainer washer 84, and die insert 92 make the removal and maintenance of the extrusion die assembly 80 easier to manage.

[0055] Referring to Figure 31, an extrusion die assembly is shown, comprising a die component 30 and a two-part insert 100 that is received into an opening 32 within the die component 30. The two-part insert 100 may include two segments (identical or different) that together define a die orifice 24 of any shape disclosed herein. In the illustrated embodiment, the die orifice is an elongated slot having half of the orifice 24 defined by each segment 100a, 100b. The two-part insert 100 may be intentionally provided with a dividing line to facilitate assembly, disassembly, and maintenance for reuse of the insert 100. The insert 100 may be made from WC, WLa, Wre, high-tensile steel, or another cutting tool material.

[0056] Next, an extrusion die assembly 110 with a deburring mechanism will be described with reference to Figures 32 to 36. The extrusion die assembly 110 is configured to be connected to a spindle. The extrusion die assembly 110 includes a retainer washer 112 and a die holder 114, which are connected to each other by a deburring mechanism 116 mounted between them. The retainer washer 112 may include a conical proximal (upper) surface 112a that is radially spaced away from the feed material 12. The die holder 114 may include a polygonal recess 114a for mating with the corresponding polygonal flange of an extrusion die insert, as disclosed herein. The deburring mechanism 116 is sandwiched between the retainer washer 112 and the die holder 114. The deburring mechanism 116 includes a plurality of radially inward projecting teeth 118 that project toward the feed material 12. The deburring mechanism 116 may be formed as one part as shown or as two parts. The deburring mechanism 116 defines a radial passage 116a extending radially outward between the retainer washer 112 and the die holder 114. The radial passage 116a can be defined within the integrated deburring mechanism 116 or formed between the segments of a two-part deburring mechanism. In the integrated deburring mechanism, teeth 118 can be arranged around a central hole 116b. During operation, as the feed material 12 is pressed toward the die insert and heated by friction, the feed material tends to become "mushroom-shaped" or spread radially outward. The teeth 118 of the deburring mechanism 116 cut away the radially spreading feed material, and the chips are discharged through the radial passage 116a. Thus, the deburring mechanism eliminates the problem of the feed material spreading radially outward and blocking the cavity of the extrusion die assembly 110.

[0057] Next, with reference to Figures 37 to 44, an extrusion die assembly 120 with a deburring mechanism according to an alternative embodiment will be described. The extrusion die assembly 120 is configured to be connected to a spindle. The extrusion die assembly 120 includes a retainer washer 122 and a die holder 124, which are connected to each other by one or more deburring mechanisms 126 mounted between them. The retainer washer 122 may include a conical proximal (upper) surface 122a radially spaced from the feed material 12. The die holder 124 may include a polygonal recess 124a for mating with the corresponding polygonal flange 128a of the extrusion die insert 128. The retainer washer 122 includes a recess 122b, and the die holder 124 includes a corresponding recess 124b for receiving the deburring mechanism 126 internally. The deburring mechanism 126 is sandwiched between the retainer washer 122 and the die holder 124. The deburring mechanism 126 includes a plurality of radially inwardly projecting teeth 126, which are individually clamped between the retainer washer 122 and the die holder 124 and project toward the feed material 12. The deburring mechanism feature 126 can be triangular, as shown in Figure 44, or may have other shapes. It can be made of high-strength steel, WC, WRe, WReHfC, PCBN, CBN, or other refractory alloys, or high-temperature high-strength alloys. The retainer washer 122 and the die holder 124 can define a radial passage or a plurality of passages 126a between them. The insert 132 is received within the die holder 124 and may include a die orifice of any shape as disclosed herein. During operation, as the feed material 12 is pressed toward the die insert and the feed material is heated by friction, the feed material tends to become “mushroom-shaped” or spread radially outward. The deburring teeth 126 cut off the radially expanding feed material, and the chips are discharged through the radial passage. Thus, the deburring mechanism 126 eliminates the problem of the feed material expanding radially outward and blocking the cavity in the extrusion die assembly 120.

[0058] Referring to Figure 45, an additive manufacturing system 10 according to the principles of the present disclosure is shown, comprising a cooling accessory 140 surrounding a rotary extrusion die 20. The cooling accessory 140 can provide a liquid cooling environment around the rotary extrusion die 20. Alternatively, the cooling accessory 140 can provide a cooled liquid spray or mist onto the rotary extrusion die 20. The cooling accessory can be used to control the temperature of the rotary extrusion die during the extrusion operation, or to cool the rotary extrusion die 20 more quickly at the end of the extrusion operation.

[0059] Figure 46 is a schematic diagram of an additive manufacturing system 10 equipped with a blower 150 that supplies cooling air, liquid nitrogen, liquid carbon dioxide, or any other phase-change liquid / gas / medium onto a rotary extrusion die 20. The blower 150 can provide an air-cooling environment around the rotary extrusion die 20. The blower 150 can be used to control the temperature of the rotary extrusion die during the extrusion operation or to cool the rotary extrusion die 20 more rapidly at the end of the extrusion operation.

[0060] Figure 47 is a schematic diagram of an additive manufacturing system 10, which includes a rotary extrusion die 20 for depositing additive material onto a substrate in a cooling bath 160 filled with water or other cooling fluid. The cooling bath 160 can be used to rapidly cool the extruded metal deposited on the substrate and to maintain the rotary extrusion die 20 at a desired temperature.

[0061] Figure 48 is an exemplary graph of process parameters in an additive manufacturing process relating to the principles of this disclosure. The graph shows that the rotational speed of the feed material is initially increased and maintained at increasing intervals during the preheating phase. The rotational speed during the preheating phase can be kept constant or changed as needed. For soft metal feed materials such as aluminum and soft metal alloys, the rotational speed can be in the range of 100 to 5000 RPM. For harder metal feed materials such as steel, stainless steel, and other hard metal alloys, the rotational speed can be in the range of 50 to 10,000 RPM. During the preheating phase, the feed material is preloaded with a desired pressure, which may be constant as shown in the figure or may change over time. For soft metal feed materials such as aluminum and soft metal alloys, the preload pressure can be in the range of 100 to 5000 psi. For hard metal feed materials such as steel, stainless steel, and other hard metal alloys, the preload pressure can be in the range of 100 to 10000 psi. The preheating time can be in the range of 0 to 30 minutes. Once the feed material 12 is heated to the desired extrusion temperature, the rod feed is started, and the feed rate is used to extrude the feed material into the die orifice 24 and deposit it onto the substrate in a deposition process. Alternatively, the feed material can be placed under a continuous load. For soft metal feed materials such as aluminum and soft metal alloys, the feed rate can be in the range of 1 to 2000 mm / min or a continuous load of 300 to 5000 psi. For hard metal feed materials such as steel, stainless steel, and other hard metal alloys, the feed rate can be in the range of 1 to 1000 mm / min or a continuous load of 300 to 20000 psi. The printing speed of the additive manufacturing process can be 1 to 5000 mm / min. To stop the deposition process, the feed rate is reduced to zero to remove the load and the rotation speed of the rotary extrusion die is reduced, as shown in the figure. Process parameters vary depending on the feed material and the size and diameter of the feed material.

[0062] The foregoing description of embodiments is provided for illustrative and explanatory purposes only. It is not intended to exhaustively describe or limit the disclosure. Individual elements or configurations of a particular embodiment are generally interchangeable and can be used in a selected embodiment, even if not specifically illustrated or described, where applicable. They can also be modified in a variety of ways. Such modifications should not be considered departures from the disclosure, and all such modifications are intended to be within the scope of the disclosure.

Claims

1. An additive manufacturing system for adding a supply material to a substrate, wherein the additive manufacturing system is A supply material supply system configured to supply the aforementioned supply material, A rotary extrusion die system having a drive system configured to rotate the extrusion die member in relative and physical contact with the feed material, thereby generating sufficient friction to locally heat and soften the non-rotating feed material. An additive manufacturing system comprising, wherein the rotary extrusion die member has an extrusion orifice, and the heated and softened feed material is extruded through the extrusion orifice.

2. The additive manufacturing system according to claim 1, wherein the extrusion die member does not come into contact with the feed material in any tangential or circumferential direction, and the feed material does not rotate in any case.

3. The additive manufacturing system according to claim 1, wherein the extrusion die member is arranged at a distance from the substrate.

4. The additive manufacturing system according to claim 1, wherein the extrusion die system having the rotational drive system is configured to generate sufficient friction to provide a plastically deformable feed material that is extruded and deposited through the extrusion orifice of the extrusion die system, by rotating the extrusion die member in relative and physical contact with the feed material, thereby locally heating the feed material to plasticize it.

5. The additive manufacturing system according to claim 4, wherein the extrusion die member has an outer surface adjacent to the orifice, and the outer surface is configured to engage with a deposited plastically deformable feed material.

6. The additive manufacturing system according to claim 1, wherein the extrusion die member includes one of a bowtie-shaped, dogbone-shaped, and Y-shaped orifice.

7. The additive manufacturing system according to claim 1, wherein the extrusion die member includes an eccentric orifice.

8. The additive manufacturing system according to claim 1, wherein the extrusion die member includes a slot-shaped orifice.

9. The additive manufacturing system according to claim 1, wherein the supply material has a square cross-sectional shape.

10. The additive manufacturing system according to claim 1, wherein the supply material has a circular cross-sectional shape.

11. The additive manufacturing system according to claim 1, wherein the extrusion orifice includes a plurality of orifices.

12. The additive manufacturing system according to claim 1, wherein the extrusion die member includes a die retainer having an opening inside and an insert received in the opening, and the extrusion orifice extends through the insert.

13. The additive manufacturing system according to claim 12, wherein the die member includes a plurality of mounting holes inside.

14. The additive manufacturing system according to claim 12, wherein the insert is composed of two parts.

15. The additive manufacturing system according to claim 1, wherein the extrusion die member is connected to the drive system via an insulating washer.

16. The additive manufacturing system according to claim 1, wherein the feed material supply system includes a channel and an end nut detachably attached to the distal end of the channel and having a hole from which the feed material is dispensed.

17. The additive manufacturing system according to claim 16, further comprising a retainer washer positioned opposite the end nut.

18. The additive manufacturing system according to claim 1, further comprising a burr cutting mechanism attached to the rotary extrusion die system.

19. The additive manufacturing system according to claim 18, wherein the burr cutting mechanism includes a radial passage.

20. The additive manufacturing system according to claim 1, wherein the rotary extrusion die system includes one of a liquid cooling system, a gas cooling system, or an air cooling system.

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