Powder Removal from Additive Manufacturing Components
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Solution Overview
Problem
Existing methods for removing unconsolidated powder from additive layer manufactured components, especially those with complex geometries, are inefficient and can cause mechanical damage or lead to sintering, which affects component performance and introduces contamination risks.
Innovation Solution
A method involving the saturation of unconsolidated powder with water, followed by temperature changes to expand the fluid and loosen the powder, and subsequent vibration to remove it through apertures, effectively addressing the issue of entrapped powder in complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vibration or ultrasonic bath is used to remove powder, then powder removal is attempted, but the process is time consuming and not entirely effective
Solution Approach 1:
The patent applies phase transition by freezing water to ice and then thawing it back to liquid state. The freezing phase causes water to expand and dislodge compacted powder, while the thawing phase allows the loosened powder to be removed. This phase transition mechanism resolves the contradiction by providing effective powder removal without requiring prolonged vibration or ultrasonic treatment.
Solution Approach 2:
The patent changes the temperature parameter of water from liquid state to frozen state and back. By controlling temperature variations, the method achieves powder loosening and removal effectively. This parameter change approach eliminates the need for time-consuming vibration processes while maintaining high removal efficiency.
2Productivity
If high-pressure fluid or implements are used to extract powder, then powder can be loosened and extracted, but the component may be mechanically damaged
Solution Approach 1:
The patent uses the phase transition of water from liquid to solid and back to liquid to extract powder. The freezing water expands and gently pries loose compacted powder without applying concentrated mechanical force that could damage the component. This resolves the contradiction by achieving effective extraction while avoiding mechanical damage through a gentler physical mechanism.
Solution Approach 2:
The patent replaces mechanical extraction methods (high-pressure fluid injection or physical implements) with a thermal-phase transition mechanism. Instead of using forceful mechanical means that risk damaging complex internal features, the method uses controlled freezing and thawing cycles to naturally loosen and remove powder, thereby eliminating the harmful mechanical damage while maintaining extraction effectiveness.
3Productivity
If vibration is used to remove powder from complex features, then some powder may be dislodged, but entrapped powder remains and can sinter to the component
Solution Approach 1:
The patent employs phase transition of water to ice and back to thoroughly remove entrapped powder from complex features. The expanding ice penetrates and loosens even tightly compacted powder that vibration cannot reach, ensuring complete removal. This prevents sintering and maintains component reliability while the thawing phase allows complete powder evacuation, resolving the contradiction between removal capability and preventing residual powder damage.
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 reliably removes unconsolidated powder from complex geometries, improving component performance and preventing sintering-related issues, such as in gas turbine engine components with internal cooling channels.
Implementation Method 1
reducing the temperature of the saturated unconsolidated powder material to a temperature below the freezing temperature of the water; allowing the water to freeze
Implementation Method 2
introduction of water whose volume increases upon reduction of the temperature of the fluid to below its solidification temperature
Implementation Method 3
removing the unconsolidated powder material from the volume
Data Source
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Figure 2
AI summary
An additive layer manufactured component has a first wall portion and a second wall portion with a volume defined between the first and second wall portions. The volume contains unconsolidated powder material. A technique for removing the unconsolidated powder involves saturating the unconsolidated powder material with a dipole fluid, reducing the temperature of the saturated unconsolidated powder material to a temperature below the freezing temperature of the dipole fluid, and then allowing the dipole fluid to freeze. The temperature of the saturated unconsolidated powder material is then raised to a temperature above the melting temperature of the dipole fluid, whereupon the unconsolidated powder material may be removed from the volume.