AFS Tool Head Barrier for Flash-Constrained Layer Deposition
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Solution Overview
Problem
Additive Friction Stir (AFS) manufacturing processes generate significant flash, requiring costly and time-consuming secondary machining processes to remove, which increases production time and cost, and reducing layer thickness only exacerbates the issue by increasing the number of layers needed.
Innovation Solution
A tool head assembly with a barrier extending along the side surface of the layer to constrain material from extruding past the shoulder, reducing flash generation and eliminating the need for secondary machining processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If AFS process uses friction to constrain material flow, then material can be deposited, but significant flash is generated that requires secondary machining
Solution Approach 1:
A barrier element is introduced as an intermediary component between the tool head shoulder and the substrate. This barrier physically blocks the plasticized material from extruding past the shoulder edge, preventing flash formation while allowing the friction stir deposition process to continue effectively.
Solution Approach 2:
The tool head assembly is segmented into distinct functional components: the rotating tool head with shoulder for friction stir, the barrier element for flash prevention, and the substrate. This segmentation allows the barrier to be positioned optimally to block material flow without interfering with the friction stir process.
2Object-generated harmful factors
If layer thickness is reduced to generate less flash, then flash amount decreases, but number of layers increases which increases build time and cost
Solution Approach 1:
The barrier element serves as a mediator that enables the use of thicker layers without generating excessive flash. By physically blocking material extrusion at the shoulder edge, the barrier allows optimal layer thickness to be maintained, preserving build rate while eliminating flash problems.
3Manufacturing precision
If secondary machining processes are added to remove flash, then manufacturing precision improves, but production time and cost increase
Solution Approach 1:
The barrier element performs the flash prevention action during the primary deposition process itself, rather than requiring a subsequent machining operation. The barrier is in place during layer deposition, preventing flash formation at the source, which eliminates the need for later corrective machining operations.
4Ease of manufacture
If friction between material and shoulder is used to constrain flow, then material deposition is achieved, but material extrudes past shoulder edge forming flash
Solution Approach 1:
The barrier element acts as a mechanical intermediary that enhances the constraining capability. While friction provides some constraint, the barrier element provides a physical wall that definitively blocks material flow at the shoulder edge, ensuring precise material confinement without complicating the deposition process.
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
Significantly reduces flash generation, minimizing the duration and number of secondary finishing processes, thereby reducing production time and cost while maintaining efficient layer deposition.
Implementation Method 1
a shoulder configured to contact the material such that rotation of the tool head frictionally stirs the material
Implementation Method 2
Under axial loading and rotation, the feed material is locally heated and plasticized
Implementation Method 3
a barrier configured to extend along a side surface of the at least one layer as the at least one layer is deposited onto the substrate such that the barrier is configured to constrain the material from extruding past an edge of the shoulder
Data Source
AI summary
A tool head assembly for a solid state additive manufacturing apparatus includes a tool head having a material passage configured to receive a material therein. The tool head is configured to deposit the material from the material passage onto a substrate of the solid state additive manufacturing apparatus to form at least one layer of the material on the substrate. The tool head includes a shoulder configured to contact the material such that rotation of the tool head frictionally stirs the material. The tool head assembly includes a barrier configured to extend along a side surface of the at least one layer as the at least one layer is deposited onto the substrate such that the barrier is configured to constrain the material from extruding past an edge of the shoulder.