Additive Micro-Forging of Solidified Layers for Grain Refinement
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Solution Overview
Problem
Additive manufacturing methods using the 'melting-solidification' technique produce coarse, directionally oriented crystals, making it difficult to achieve comprehensive performance comparable to forged materials, and the complexity of combining melting with forging processes limits control over forging conditions, affecting material quality and application scope.
Innovation Solution
A composite forming system integrating additive manufacturing with real-time micro-forging, utilizing a material conveyor and energy source to fuse material and a micro-forging device with two forging hammers to generate controlled deformations, allowing for precise refinement of solidified portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the 'melting-solidification' method is used to manufacture parts, then the manufacturing process can be achieved, but the internal microstructure becomes coarse with obvious directionality, making it difficult to achieve comprehensive performance comparable to forged materials
Solution Approach 1:
The patent combines additive manufacturing with real-time micro-forging into a single integrated process. The micro-forging device is positioned directly in the melt pool area, allowing simultaneous deposition and forging operations. This merging enables the solidified structure to undergo plastic deformation that refines the coarse crystalline structure while maintaining the manufacturing advantages of additive processes.
Solution Approach 2:
The micro-forging operation is performed immediately after material deposition while the material is still in a semi-solid or hot state. This preliminary action refines the microstructure during the forming process itself, before the material fully solidifies and cools, preventing the formation of coarse directional crystals in the first place.
2Manufacturing precision
If the method of combining melting with forging is used, then the internal quality can be improved to some extent, but the high complexity of the process and equipment affects the control over forging conditions
Solution Approach 1:
The micro-forging device serves multiple functions: it provides mechanical deformation to refine microstructure, controls local plastic flow, and influences heat distribution in the melt pool. This multi-functionality reduces the need for separate post-processing operations and simplifies the overall process control by integrating multiple effects into a single device.
Solution Approach 2:
The patent controls forging conditions by adjusting parameters such as hammer impact force, frequency, and positioning relative to the melt pool. These parameter changes enable precise control over the micro-forging process without requiring complex equipment, as the same device can operate across a range of conditions by simply modifying operational parameters.
3Strength
If the method of combining melting with forging is used, then the mechanical properties can be enhanced, but the rapid solidification and cooling rate prevents effective control over temperature and other forging parameters
Solution Approach 1:
The micro-forging operation continues throughout the additive manufacturing process, with hammers continuously impacting the melt pool as material is deposited. This continuous action maintains plastic deformation and microstructure refinement throughout the entire building process, rather than as a separate intermittent step, enabling better temperature and parameter control through sustained operational feedback.
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 enhances the mechanical properties and internal quality of manufactured parts by enabling precise control over forging conditions, reducing internal defects, and improving the performance of additive manufactured materials.
Implementation Method 1
The energy source is configured to direct an energy beam toward the material, the energy beam fuses at least a portion of the material to form a solidified portion
Implementation Method 2
the energy beam fuses at least a portion of the material to form a solidified portion
Implementation Method 3
the first forging hammer is configured to impact the solidified portion to generate a first deformation
Implementation Method 4
the first forging hammer is configured to impact the solidified portion to generate a first deformation
Implementation Method 5
the second forging hammer is configured to impact the solidified portion to generate a second deformation greater than the first deformation
Implementation Method 6
the second forging hammer is configured to impact the solidified portion to generate a second deformation greater than the first deformation
Data Source
AI summary
The present invention relates to an additive manufacturing system and its methods. The system includes a material conveyor, an energy source, and a micro-forging device. The material conveyor is configured to convey material. The energy source is configured to direct an energy beam toward the material, the energy beam fuses at least a portion of the material to form a solidified portion. The micro-forging device is movable along with the material conveyor for forging the solidified portion, wherein the micro-forging device comprises a first forging hammer and a second forging hammer, the first forging hammer is configured to impact the solidified portion to generate a first deformation, and the second forging hammer is configured to impact the solidified portion to generate a second deformation greater than the first deformation.