Additive Manufacturing Alloy Design via Primitive Material Mixture
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Solution Overview
Problem
Traditional alloy design and manufacturing methods are resource-intensive and time-consuming, leading to reliability issues due to changes in size, processing route, and purity, especially in large-scale alloy production.
Innovation Solution
A method using additive manufacturing that involves supplying a mixture of primitive materials at target spots, melting, and solidifying them to form a metallic structure of an alloy, allowing for precise control of material distribution and properties through techniques like selective laser melting, electron beam melting, and mechanical mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional alloy design and manufacturing methods are used, then manufacturing precision and reliability can be maintained, but the process is resource-intensive and time-consuming
Solution Approach 1:
The patent applies preliminary action by pre-mixing primitive materials in specific ratios before the additive manufacturing process. This pre-prepared mixture is then directly deposited and melted at target spots, eliminating the need for time-consuming on-site alloying operations and significantly accelerating the manufacturing cycle.
Solution Approach 2:
The patent replaces traditional mechanical mixing and casting processes with additive manufacturing technology. By using selective laser melting or electron beam melting on deposited material mixtures, the process eliminates conventional mechanical alloying steps, reducing both time and resource consumption while maintaining manufacturing precision.
2Reliability
If traditional alloy manufacturing is used, then process reliability is maintained, but changes in size, processing route, and purity lead to reliability issues
Solution Approach 1:
The patent applies local quality by enabling different primitive material compositions to be deposited and melted at specific target spots within the same manufacturing process. This allows spatial variation in alloy composition and properties to be precisely controlled, adapting to different functional requirements while maintaining overall process reliability through standardized deposition and melting parameters.
Solution Approach 2:
The patent introduces dynamics by allowing real-time adjustment of material deposition rates, mixture ratios, and energy source parameters during the manufacturing process. This dynamic control enables the system to adapt to varying design requirements and maintain reliable alloy properties despite changes in processing conditions.
3Productivity
If additive manufacturing with primitive material mixtures is used, then productivity and design speed are improved, but manufacturing precision must be controlled
Solution Approach 1:
The patent applies feedback by implementing monitoring and control mechanisms during the additive manufacturing process. Sensors detect parameters such as melt pool temperature, material deposition rate, and layer thickness, providing real-time feedback to adjust processing parameters and ensure precise material distribution and alloy composition throughout the manufactured structure.
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
This approach enables rapid alloy design with improved mechanical properties, such as enhanced strength, ductility, and grain refinement, reducing production costs and time while maintaining high reliability, suitable for complex structural applications.
Implementation Method 1
step (b) comprises melting the mixture with a laser beam or an electron beam or an arc beam
Implementation Method 2
step (b) comprises melting the mixture with a laser beam or an electron beam or an arc beam
Implementation Method 3
step (b) comprises melting the mixture with a laser beam or an electron beam or an arc beam
Implementation Method 4
melting and solidifying the mixture disposed at the target spot to form a portion of a metallic structure
Implementation Method 5
mixing the plurality of primitive materials to form the mixture by mechanical vibrating, ultrasonic vibrating, stirring, and/or grinding
Implementation Method 6
mixing the plurality of primitive materials to form the mixture by mechanical vibrating, ultrasonic vibrating, stirring, and/or grinding
Data Source
AI summary
A method and a system for manufacturing a structure includes the steps of: (a) supplying a mixture consisting a plurality of primitive materials at a target spot; (b) melting and solidifying the mixture disposed at the target spot to form a portion of a metallic structure consisting of an alloy of the plurality of the primitive materials; and (c) repeating steps (a) and (b) at a plurality of target spots in a three-dimensional space to produce the metallic structure of the alloy.