AFSD Feedstock Bar Staging for Continuous Spindle Loading
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Solution Overview
Problem
In additive friction stir deposition (AFSD) manufacturing, the process of loading feedstock bars one-by-one interrupts spindle rotation, reduces deposition rate, and results in material cooling and waste, limiting part quality and geometry complexity.
Innovation Solution
A container system with a staging mechanism to hold multiple feedstock bars, allowing continuous deposition without stopping spindle rotation, using mechanisms like helicoid springs, chains, and gears to align and load bars into the spindle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If feedstock bars are loaded one-by-one into the spindle, then the deposition process can be performed, but the spindle rotation must be stopped and the deposition rate is reduced
Solution Approach 1:
Multiple feedstock bars are pre-loaded into the container before the deposition process begins. The staging mechanism prepares subsequent bars in advance, so when one bar is depleted, another is already positioned and ready for immediate transfer to the spindle, eliminating interruptions and maintaining continuous spindle rotation.
Solution Approach 2:
The system enables continuous deposition by maintaining uninterrupted spindle rotation. The container with multiple pre-loaded bars and the automated staging mechanism ensure that feedstock supply never interrupts the deposition process, allowing the spindle to rotate continuously and deposit material without stopping.
2Quantity of substance
If the spindle is moved to an intermediate location to reload feedstock, then feedstock can be replenished, but the overall deposition rate is reduced due to movement time
Solution Approach 1:
A container acts as an intermediary storage device between the feedstock bars and the spindle. Multiple bars are stored in the container, and a staging mechanism serves as an intermediary transfer system that automatically positions and transfers bars to the spindle without requiring the spindle to move to intermediate locations, thereby maintaining continuous deposition.
3Ease of operation
If feedstock bars are loaded one-by-one, then the process can be controlled, but operator intervention is required and part quality is reduced due to cooling periods
Solution Approach 1:
The staging mechanism is configured to automatically transfer feedstock bars from the container to the spindle without operator intervention. The system serves itself by detecting when a bar is depleted and autonomously positioning the next bar, eliminating the need for manual reloading and preventing cooling interruptions that would compromise part quality.
4Productivity
If the entire feedstock bar is not deposited before reloading, then continuous operation can be maintained, but material waste occurs at the terminal portion of each bar
Solution Approach 1:
Multiple feedstock bars are pre-loaded into the container before deposition begins. This preliminary preparation ensures that when one bar is nearly depleted, another bar is already in position and ready for immediate transfer, allowing the system to use the entire length of each bar including the terminal portion without interruption or waste.
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 increases deposition rate, reduces operator intervention, minimizes material cooling, and enables the deposition of entire feedstock bars, enhancing part quality and geometrical complexity while reducing waste.
Implementation Method 1
an additive material is deposited onto a substrate or previously formed layers via frictional forces that stir and deform the material
Implementation Method 2
a spindle receives an additive material and is rotated to impart frictional forces to the material at the material/substrate interface to thereby stir, soften, and deposit the material
Data Source
AI summary
A method for loading feedstock bars into an additive friction stir deposition machine (AFSD) is described. The method comprises containing a plurality of feedstock bars in a container disposed adjacent to a spindle of the additive friction stir deposition machine. The method further comprises moving one feedstock bar of the plurality of feedstock bars into axial alignment with the spindle of the additive friction stir deposition machine.