Additive Manufacturing Gas Purification via Hydrogen Oxidation

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Solution Overview

Problem

Additive manufacturing processes face challenges in controlling the process gas atmosphere within the process chamber, particularly in managing oxygen content and humidity, which can lead to contamination and variations in the mechanical properties of manufactured components.

Innovation Solution

A method involving the circulation of process gas with hydrogen, where oxygen reacts with hydrogen to form water vapor, which is then condensed out, allowing for controlled reduction of oxygen content and humidity levels within the process chamber, ensuring a consistent and reproducible manufacturing environment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the process chamber is opened for removing manufactured components and manufacturing new components, then productivity is improved, but oxygen content in the process gas increases causing contamination

Engineering Contradiction:

Improvemanufacturing throughputVSAvoidoxygen content

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces hydrogen into the process gas, which reacts with the harmful oxygen to form water vapor. This converts the harmful oxygen contamination into a manageable water vapor that can be removed through condensation, thus transforming the harmful effect into a beneficial purification process

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent changes the composition parameter of the process gas by adding hydrogen to react with oxygen. It also changes the temperature parameter by cooling the process gas to condense water vapor, thereby controlling oxygen content through parameter modification rather than simple exclusion

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If hydrogen is added to react with oxygen, then oxygen content is reduced, but water vapor increases causing humidity control challenges

Engineering Contradiction:

Improveoxygen contentVSAvoidwater vapor content

Core Design Contradiction:

Object-affected harmful factorsVSObject-generated harmful factors

Solution Approach 1:

The patent utilizes the phase transition of water vapor to liquid water through cooling. By reducing the temperature of the process gas, water vapor condenses into liquid form that can be easily separated and removed, thus controlling humidity while maintaining oxygen removal benefits

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The water vapor produced by the hydrogen-oxygen reaction is not simply discarded but is converted into a condensable form. This transforms the harmful water vapor into a removable liquid phase, turning a potential problem into a manageable byproduct that can be efficiently separated

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If the process gas is circulated and recirculated, then productivity is improved, but contamination accumulates over time

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidcontamination level

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent implements a feedback mechanism where the process gas is continuously monitored for oxygen and water vapor content. Based on these measurements, hydrogen is dynamically adjusted to maintain optimal reaction conditions, and the cooled gas is recirculated only after contamination has been removed, ensuring continuous purification

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent selectively discards the harmful components (oxygen and water vapor) from the recirculated process gas while recovering and recirculating the beneficial inert gas atmosphere. This separation allows continuous recycling of the process gas without accumulation of contaminants

Inventive Principle:

Principle #34Discarding and recovering

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 precise control of the process gas atmosphere, reducing contamination and ensuring consistent mechanical properties of the manufactured components by effectively managing oxygen and moisture levels, thereby improving the reliability of the additive manufacturing process.

Implementation Method 1

oxygen reacts with hydrogen to form water vapor

Methodology Applied

Scientific EffectChemical reaction (oxidation): Oxidation

Implementation Method 2

the cycle gas enriched with hydrogen is heated to a temperature of more than 500.degree. C., more than 600.degree. C. or more than 700.degree. C.... the cycle gas is subsequently cooled to a temperature of less than 60°C, less than 40°C or less than 20°C

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentEP3318351B1Method for the generative production of a three-dimensional component

Publication Date: 2020.12.30 AIRBUS DEFENCE & SPACE GMBH

Figure 1

AI summary

The invention relates to a method and a device for the additive manufacturing of a three-dimensional component in a process chamber, wherein the steps – providing a metallic starting material in the process chamber – melting the starting material by supplying energy are repeated multiple times. A process gas is circulated through the process chamber. Hydrogen is added to the circulating gas, which is then heated to a temperature of more than 500 °C and subsequently cooled to a temperature of less than 60 °C.