AFSD Shoulder with Wire Brush and Gas Shroud for Bond Quality
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive friction stir deposition (AFSD) systems face challenges with surface preparation, as it typically occurs minutes or hours before deposition, leading to opportunities for oxidation and contamination.
Innovation Solution
The proposed solution involves an AFSD device with a shoulder, wire brush skirt, and gas shroud, which allows for continuous in-situ surface preparation. The device includes a channel for filler material deposition and a gas shroud for contaminant removal, enabling simultaneous surface preparation and deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surface preparation occurs minutes or hours prior to deposition, then surface preparation can be completed, but oxidation and contamination increase
Solution Approach 1:
The wire brush skirt performs surface preparation (scratch brushing) immediately before deposition in a preliminary action, removing contaminants and creating surface roughness right before the filler material is deposited, eliminating the time gap that causes oxidation
Solution Approach 2:
The gas shroud creates an inert or protected atmosphere around the deposition zone using pressurized gas flow, preventing oxidation and contamination of the surface and deposited material by isolating them from ambient air during the critical preparation and deposition phases
2Object-affected harmful factors
If surface preparation occurs immediately before deposition, then oxidation and contamination are reduced, but the process complexity increases
Solution Approach 1:
The device merges multiple functions into a single integrated tool: the rotating shoulder performs friction stir deposition, the wire brush skirt performs surface preparation, and the gas shroud provides atmospheric protection, all simultaneously in one device assembly
Solution Approach 2:
The shoulder assembly serves multiple functions: it deposits filler material through friction stir, prepares the surface through wire brush contact, and controls the atmospheric environment through the gas shroud, making it a multi-functional tool head
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 solid-state bond formation during additive manufacturing by reducing oxidation and contamination, improving the mechanical performance and properties of the deposited material.
Implementation Method 1
The wire brush skirt is configured to scratch the deposition surface as the device is advanced along the deposition surface
Implementation Method 2
The gas shroud includes an inlet configured to direct pressurized gas through the plurality of openings in the collar. The pressurized gas is configured to remove contaminants as the device is advanced along the deposition surface
Implementation Method 3
additive friction stir deposition (AFSD) systems, devices, and methods
Data Source
AI summary
An additive friction stir deposition device is provided. In one aspect, the device includes a shoulder configured to rotate about a central axis. The shoulder includes a channel extending from a first end of the shoulder to a second end of the shoulder. The channel allows a filler material to pass through the shoulder from the first end towards the second end. The shoulder configured to deposit the filler material as the device is advanced along a deposition surface. The device also includes a wire brush skirt configured to co-rotate with the shoulder and contact the deposition surface as the device is advanced along the deposition surface. The device also includes a gas shroud configured to direct pressurized gas toward the deposition surface and remove contaminants as the device is advanced along the deposition surface.