Additively Manufactured Internal Threads for Hard Metal Alloys
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Solution Overview
Problem
Amorphous metal alloys are difficult to machine due to their hardness, leading to inaccuracies and high costs in producing internal threads, especially with conventional methods like thread cutting.
Innovation Solution
The use of additive manufacturing processes, such as selective laser melting or electron beam melting, to create metal threaded elements with internal threads, allowing for layer-by-layer production of complex structures without the need for post-processing and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining methods (cutting or milling) are used to produce internal threads in amorphous metal alloys, then the threads can be manufactured with conventional equipment, but the hardness of amorphous alloys leads to machining difficulties, inaccuracies in thread production, and increased technical complexity
Solution Approach 1:
The patent replaces conventional mechanical machining methods (cutting or milling) with an additive manufacturing process. Instead of removing material through mechanical forces that struggle against the hardness of amorphous alloys, the invention builds the threaded structure layer by layer using controlled deposition and selective melting of metal powder, thereby avoiding machining difficulties while achieving precise thread geometry
Solution Approach 2:
The invention changes the manufacturing approach from subtractive (machining) to additive (layer-by-layer construction). By altering the fundamental manufacturing parameter from mechanical removal to controlled material deposition and selective melting, the process overcomes the hardness-related machining limitations of amorphous alloys while maintaining thread precision
2Ease of manufacture
If conventional machining methods are used to produce internal threads in amorphous metal alloys, then existing manufacturing equipment can be utilized, but the process becomes very costly due to the complexity and material waste
Solution Approach 1:
The patent replaces conventional mechanical thread cutting processes with additive manufacturing. This substitution eliminates the need for complex machining operations and significantly reduces material waste, as additive manufacturing deposits material only where needed rather than removing large portions of the workpiece, thereby lowering both manufacturing costs and material loss
Solution Approach 2:
The invention minimizes material waste by using additive manufacturing to build threads directly in their final form. Any excess powder material can be collected and reused in subsequent manufacturing processes, further reducing material loss and manufacturing costs compared to conventional machining where material is permanently removed
3Productivity
If additive manufacturing processes are used to produce threaded elements from metal powder, then complex structures can be created with minimal post-processing, but the surface roughness of the threaded section must be controlled within specific ranges to ensure functionality
Solution Approach 1:
The invention optimizes additive manufacturing parameters (laser power, scan speed, layer thickness, hatch spacing) to achieve the desired surface roughness range (Rz 2.5-60 μm) directly during the manufacturing process. By carefully controlling these parameters, the process produces functional threads with appropriate surface characteristics without requiring extensive post-processing, thereby maintaining high productivity while achieving precision surface finish
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 method enables the cost-effective and energy-efficient production of threaded elements with precise internal threads from amorphous alloys and precious metals, suitable for high-tech applications, while avoiding the inaccuracies associated with traditional machining.
Implementation Method 1
selective laser melting (SLM)
Implementation Method 2
selective electron beam melting (SEBM)
Implementation Method 3
The threaded element can be produced by selectively melting a metallic powder material, for example, by means of an electron beam or laser beam
Data Source
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AI summary
The present invention relates to a threaded element comprising or consisting of a metal with an internal thread, produced by additive manufacturing, and to a method for producing a threaded element comprising or consisting of a metal with an internal thread. The threaded element comprises a body, an opening defining an inner wall of the body, and a threaded section. The body comprises a first end and a second end. The opening extends at least partially from the first end toward the second end of the body. The threaded section is formed on the inner wall of the opening, and the inner wall has at least one recess that intersects the threaded section. A surface of the threaded section has a roughness Rz in the range of 5–50 µm, particularly 10–25 µm.