Additive Manufacturing Forging Head With Through-Hole Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing additive manufacturing methods using the 'melting-solidification' method produce coarse, directionally oriented crystals, making it difficult to achieve comprehensive performance comparable to forged materials, and the high-temperature processing conditions lead to frequent damage and inefficiency of the forging head in composite machining processes.
Innovation Solution
A forging head with a base portion and a forging portion that includes a through hole for an energy beam and additive material to pass through, allowing real-time forging and peening of the cladding layer during additive manufacturing, along with a fixing device for the forging head that includes a cavity for coolant circulation to prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the 'melting-solidification' method is used for additive manufacturing, then material deposition and metallurgical bonding are achieved, but coarse directionally oriented crystals are produced making it difficult to achieve comprehensive performance comparable to forged materials
Solution Approach 1:
The patent combines additive manufacturing with forging processes in a hybrid system. The forging head integrates both deposition functions (for material addition) and forging functions (for consolidation and microstructure refinement), enabling simultaneous melting-solidification and mechanical working to produce fine equiaxed crystal structures while maintaining complex geometry capability
Solution Approach 2:
The patent changes the processing parameters by introducing controlled thermal cycles and mechanical stress conditions during additive manufacturing. Through parameters such as laser power, scanning speed, and forging pressure, the system transforms the crystal structure from coarse directional grains to fine equiaxed grains, improving mechanical properties
2Manufacturing precision
If real-time forging is performed during cladding layer formation, then fine equiaxed crystal structures are formed and internal defects are reduced, but the device complexity increases
Solution Approach 1:
The patent designs the forging head to perform multiple functions simultaneously: material deposition, melting, consolidation, and real-time forging. This multi-functional design integrates what would traditionally be separate processes into a single tool, reducing the need for additional equipment while achieving fine equiaxed crystal structures and defect reduction
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 solution enhances the mechanical properties of the final parts by promoting recrystallization and forming fine equiaxed crystal structures, reduces internal defects, and extends the service life of the forging head by maintaining it within a suitable temperature range.
Implementation Method 1
an energy beam... for fusing at least a portion of a material added to a surface of the substrate for forming a cladding layer
Implementation Method 2
a forging portion... for forging a cladding layer during formation of the cladding layer
Implementation Method 3
a through hole which is formed through the base portion and the forging portion, for at least one of an energy beam and an additive material to pass through
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A forging head for additive manufacturing, comprising a base portion and a forging portion. The forging portion extends from the base portion for forging a cladding layer during formation of the cladding layer by additive manufacturing. The forging head further comprising a through hole which is formed through the base portion and the forging portion, for at least one of an energy bean and an additive material to pass through during formation of the cladding layer.