Additive Manufacturing System with In-Process Forging for Defect Reduction
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Solution Overview
Problem
Additive manufacturing technologies, such as 3D printing, often result in defects like porosity, cracks, and microcracks in metal parts, which affect their mechanical, electrical, and other properties, failing to meet the standards of conventional forging parts even with post-processing techniques.
Innovation Solution
An additive manufacturing system and method that incorporates a dual-energy beam process, where a first energy beam fuses material onto a substrate to form a cladding layer, and a forging device with a forging head, along with a second energy beam, heats and forges the cladding layer to eliminate defects and enhance densification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing is used to form metal parts, then complex structures can be directly formed through layering, but defects such as porosity, cracks, and microcracks are inevitably generated
Solution Approach 1:
The patent applies preliminary action by performing forging treatment on the molten material immediately after deposition while it is still in a plastic state. The forging device applies pressure to the freshly deposited layer before it solidifies completely, pre-compacting the structure and eliminating voids and cracks in advance. This preliminary densification prevents defect formation rather than addressing it after occurrence.
Solution Approach 2:
The patent utilizes parameter changes by controlling the temperature and pressure parameters during the deposition and forging process. The energy source maintains the material in a controlled molten state during deposition, then the forging device applies controlled pressure while the material is still plastic. This parameter control ensures complete fusion and densification, transforming the material state to eliminate defects while maintaining manufacturing efficiency.
2Productivity
If layer-by-layer cumulative forming is used in additive manufacturing, then parts can be formed directly, but holes, pores and other defects are generated in the final formed part
Solution Approach 1:
The patent implements continuity of useful action by integrating the forging operation directly into the deposition process. While the energy source continues to deposit material layer by layer, the forging device continuously applies pressure to the molten material immediately after deposition. This continuous action ensures that each layer is densely compacted before the next layer is deposited, eliminating voids and pores throughout the entire build process without interrupting manufacturing.
Solution Approach 2:
The patent replaces traditional post-processing mechanical methods (such as separate hot isostatic pressing or heat treatment operations) with an integrated mechanical forging approach during deposition. The forging device mechanically compacts the molten material directly during the additive manufacturing process, substituting the need for separate densification operations and achieving defect elimination in-line with the manufacturing process itself.
3Ease of manufacture
If conventional additive manufacturing process is used, then material can be added to substrate surface, but mechanical properties cannot meet the standard of conventional forging parts
Solution Approach 1:
The patent merges the additive manufacturing process with a forging process, combining material deposition and mechanical densification into a single integrated operation. The energy source deposits material while the forging device simultaneously applies pressure to compact and densify the material. This merging of processes eliminates the weaknesses of conventional additive manufacturing by incorporating the densification step directly into the deposition process, achieving mechanical properties comparable to conventional forging parts.
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
The system effectively reduces defects, increases densification, and improves the microstructure of final parts, ensuring they meet the performance standards of conventional forging parts by maintaining a stable forging temperature during the additive manufacturing process.
Implementation Method 1
moving a first energy beam along a surface of a substrate to fuse at least a portion of a material added to the surface of the substrate for forming a cladding layer on the substrate
Implementation Method 2
Heating a forging area of the cladding layer using a second energy beam
Implementation Method 3
The forging head is configured to forge the cladding layer during formation of the cladding layer
Data Source
AI summary
An additive manufacturing system, comprises an energy source device for providing a first energy beam and a second energy beam; and a forging device comprising a forging head. The first energy beam and a substrate are configured to move relative to each other to fuse at least a portion of a material added to the surface of the substrate for forming a cladding layer on the substrate. The forging head is configured to forge the cladding layer during formation of the cladding layer. The second energy beam is configured to heat a forging area of the cladding layer.