Metal Additive Manufacturing System with Integrated Forging Element
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Solution Overview
Problem
Metal additive manufacturing faces challenges with inhomogeneous mechanical and metallurgical properties, particle shrinkage, and porosity in large-scale complex components due to rapid melting, solidification, and cooling processes.
Innovation Solution
A metal additive manufacturing system that incorporates a forging element with a controlled force application mechanism, allowing force to be exerted from both above and below the part, using a sliding mechanism and transmission elements to distribute force evenly, and a control unit to manage the position and orientation of the part and forging surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If metal additive manufacturing is performed with rapid melting, solidification and cooling, then manufacturing speed and productivity are improved, but inhomogeneous mechanical and metallurgical properties, particle shrinkage and porosity occur
Solution Approach 1:
The patent applies preliminary action by performing hot forging during the additive manufacturing process itself, before the part is completely manufactured. The hot forging element is integrated into the manufacturing system and applies heat and pressure to each layer as it is deposited, pre-treating the material to improve microstructure and reduce defects before subsequent layers are added. This prevents the formation of inhomogeneous properties rather than correcting them after manufacturing.
Solution Approach 2:
The patent utilizes parameter changes by controlling the temperature and pressure parameters during the additive manufacturing process. The hot forging element maintains the material at elevated temperatures during deposition, and the system dynamically adjusts thermal and mechanical parameters to optimize microstructure formation. This controlled parameter variation ensures homogeneous mechanical and metallurgical properties while maintaining high manufacturing speed.
2Manufacturing precision
If forging is performed during additive manufacturing process, then particle shrinkage and porosity are reduced, but device complexity increases
Solution Approach 1:
The patent merges the additive manufacturing process with hot forging by integrating a hot forging element directly into the manufacturing system. The forging element is positioned within the build chamber and operates simultaneously with the material deposition process. This combination eliminates the need for separate post-processing forging operations and reduces device complexity compared to using multiple independent systems.
Solution Approach 2:
The hot forging element serves multiple functions: it heats the deposited material, applies compressive pressure to reduce porosity, and maintains temperature during layer bonding. This multi-functional component performs thermal processing, mechanical forging, and quality control in a single integrated element, reducing the need for separate devices and simplifying the overall system architecture.
3Manufacturing precision
If force is exerted from both above and below the part during manufacturing, then homogeneous distribution of mechanical properties is improved, but device complexity increases
Solution Approach 1:
The patent applies force from both above and below the part by utilizing the vertical dimension of the build chamber. The hot forging element is positioned to apply compressive force through the newly deposited layer, while the build platform provides reactive support from below. This vertical force application through the thickness of the part ensures homogeneous density and mechanical properties throughout the build volume without requiring additional lateral forcing mechanisms.
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 ensures a more homogeneous distribution of mechanical and metallurgical properties, effectively improving particle shrinkage and porosity, resulting in enhanced micro- and macrostructure quality of manufactured parts.
Implementation Method 1
The raw material is melted on the table by means of a heat source
Implementation Method 2
A forging element exerts force on the part as controlled by the user and/or automatically, thereby providing improvement in the micro- and/or macrostructure of the part
Data Source
AI summary
At least one device enables the implementation of a metal additive manufacturing method. At least one raw material is in the metal additive manufacturing method. A feeder is located on the device and enables the raw material to be deposited. A heat source is located on the device and enables the raw material from the feeder to be melted. A table enables the raw material to be processed thereon. A part is formed by melting and processing the raw material on the table using the heat source. A forging element provides improvement in the micro- and/or macrostructure of the part by exerting force on the part under the control of a user and/or automatically. A base is provided on which the device is located. A control unit enables the position of the table to be changed with respect to the base.