AM Joining Structure With Heat Sinks for Low-Distortion Welding
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Solution Overview
Problem
Additive manufacturing (AM) systems face challenges in managing heat and preventing distortion during the welding of AM components, which can lead to residual stress, material degradation, and compromised assembly integrity.
Innovation Solution
Incorporating heat management features such as thermal sinks, heat transfer passages, and phase change materials into AM components to effectively remove heat during welding, thereby stabilizing temperatures and reducing distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is performed on AM components, then joining strength is improved, but thermal distortion and residual stress increase
Solution Approach 1:
The patent extracts heat from the welding zone by introducing heat management features (thermal sinks, heat transfer passages) that remove thermal energy from the component during welding, thereby reducing thermal distortion while maintaining joining strength
Solution Approach 2:
The patent introduces phase change materials as intermediaries between the welding heat source and the component structure. These materials absorb excess heat through phase transition, mediating the thermal interaction and preventing harmful thermal distortion
2Reliability
If welding is performed on AM components, then assembly integrity is improved, but material degradation increases
Solution Approach 1:
The patent converts the harmful welding heat that causes material degradation into a beneficial process by using phase change materials to absorb and control the thermal energy. The harmful high temperature is transformed into a controlled phase transition process that protects the base material
3Manufacturing precision
If heat management features are added to AM components, then thermal distortion is reduced, but device complexity increases
Solution Approach 1:
The patent merges the heat management features directly into the component structure during additive manufacturing. Thermal sinks, heat transfer passages, and phase change material chambers are integrated into the component geometry, eliminating separate heat management devices and reducing overall system complexity
4Stability of the object's composition
If heat management features are added to AM components, then residual stress is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes the unique capability of additive manufacturing to change geometric parameters and internal structures that are impossible with conventional manufacturing. Complex internal heat management features are created by changing the manufacturing process parameters, making previously unmanufacturable heat management solutions accessible
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
The implementation of heat management features within AM components significantly reduces thermal distortion and residual stress, enhancing the structural integrity and performance of welded assemblies.
Implementation Method 1
heat transfer passages
Implementation Method 2
phase change materials
Implementation Method 3
thermal sinks
Data Source
AI summary
An additively manufactured component and method for producing a component from multiple components by welding or adhering an additively manufactured component to a second component. The additively manufactured component includes a joining portion configured to be welded to the second component, and a heat management feature for removing heat from the joining portion.