7050 Aluminum Solid-State Additive Manufacturing for Thick Parts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of thick, complex aluminum alloy parts using 7050-type aluminum alloy is hindered by strength, cost, and lead time issues in traditional forging and extrusion processes, and existing additive manufacturing methods require melting or expensive powder metallurgy, limiting scalability and cost-effectiveness.
Innovation Solution
Solid-state additive manufacturing (SSA) using a 7050-type aluminum alloy with a friction stir process that builds parts in a solid state without melting, allowing for large, complex geometries with minimal voids and high strength, achieved by controlling deposition temperature and microstructure through a system comprising a feeding unit, spindle, tool, and temperature sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional forging or extrusion processes are used to produce thick, complex aluminum alloy parts, then the parts can achieve high strength, but the production cost increases and lead time extends due to expensive tooling and complex process requirements
Solution Approach 1:
The patent changes the fundamental processing parameters by transitioning from melting-based additive manufacturing to solid-state additive manufacturing. The deposition temperature is controlled below the melting point of aluminum (specifically 360-485°C for 7050 alloy), and the material is deposited in a solid state rather than liquid. This parameter change eliminates the need for expensive tooling while achieving comparable or superior mechanical properties through controlled microstructure development.
Solution Approach 2:
The patent replaces the mechanical forging/extrusion tooling system with a solid-state deposition system. Instead of using expensive dies and molds required for forging and extrusion, the invention uses a deposition tool that builds parts layer by layer in solid state, eliminating tooling costs while maintaining or improving part strength through controlled equiaxed grain formation.
2Shape
If existing additive manufacturing methods are used to produce aluminum alloy parts, then complex geometries can be achieved, but the process requires melting or expensive powder metallurgy, limiting scalability and cost-effectiveness
Solution Approach 1:
The patent fundamentally changes the deposition state parameter from liquid (melting-based AM) or powder (powder metallurgy) to solid state. The aluminum alloy is deposited as solid material at temperatures below its melting point, eliminating the need for expensive powder materials and melting infrastructure. This enables scalable production of complex geometries at lower costs.
Solution Approach 2:
The patent uses relatively inexpensive solid aluminum alloy material (such as 7050 alloy in rod or wire form) instead of expensive specialized AM powders. The solid state deposition process eliminates the need for costly powder metallurgy infrastructure, making the process more scalable and cost-effective for producing complex parts.
3Ease of manufacture
If solid state additive manufacturing is used to produce aluminum alloy parts, then costs and lead times are reduced with eliminated expensive tooling, but achieving high strength requires precise control of deposition temperature and microstructure
Solution Approach 1:
The patent implements temperature monitoring and control during the solid state deposition process to ensure deposition temperatures remain within the specific range of 360-485°C for 7050 aluminum alloy. This feedback control ensures consistent equiaxed grain formation and minimizes void space, achieving high strength parts while maintaining cost-effectiveness and reduced lead times.
Solution Approach 2:
The patent establishes specific deposition temperature parameters (360-485°C for 7050 alloy) that optimize microstructure formation. By controlling the deposition temperature within this range, the process achieves equiaxed grains with aspect ratios less than 2:1 and minimal void space, resulting in high strength parts without requiring expensive tooling or extended lead times.
4Ease of manufacture
If traditional manufacturing processes are used, then established production methods can be applied, but the production of thick, complex parts is hindered by strength, cost, and lead time issues
Solution Approach 1:
The patent segments the manufacturing process into controlled solid state deposition steps, building complex thick parts layer by layer. This segmentation allows for precise control of microstructure formation in each layer while eliminating the need for expensive tooling and complex forging/extrusion processes, significantly improving productivity for thick complex parts.
Solution Approach 2:
The patent transitions from traditional subtractive or formative manufacturing to additive manufacturing, adding a new dimensional approach to part production. This enables the direct building of complex three-dimensional geometries without expensive tooling, dramatically improving productivity for thick complex parts while maintaining process control through solid state deposition.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
SSA manufacturing produces parts with similar or better properties than traditional methods, reducing costs and lead times by eliminating the need for expensive tooling and allowing for thicker, stronger parts with tailored geometries, achieving high tensile strength and ductility.
Implementation Method 1
Solid-state additive manufacturing (SSA) using a 7050-type aluminum alloy with a friction stir process
Implementation Method 2
a system comprising a feeding unit, spindle, tool, and temperature sensor
Implementation Method 3
after heat treatment of the additive manufactured aluminum alloy product
Data Source
AI summary
Solid-state additive manufactured aluminum alloy products and methods of producing them are described. At least 60% percent by volume of the aluminum in the additive manufactured aluminum alloy product is present as equiaxed grains with aspect ratios less than 2:1 after heat treatment of the additive manufactured aluminum alloy product. There is minimal void space between metal atoms of the additive manufactured aluminum alloy product. Various parts including 7050-type aluminum alloy products are described.