AM Hollow Part Plug Welding for Flat Opening Closure
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Solution Overview
Problem
In additive manufacturing using the powder bed method, closing the opening portion that communicates with the hollow internal space of a fabricated object is challenging due to difficulties in ensuring surface flatness and minimizing heat input, especially when using TIG welding, and LMD methods struggle with closing bottomless openings.
Innovation Solution
A method involving forming a plug using metal powder, mounting it within the opening portion, and welding it to the fabricated object using an energy beam to effectively close the opening while maintaining the same material composition and minimizing heat-induced deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If TIG welding is used to close the opening portion, then the opening can be sealed, but the surface flatness cannot be ensured and heat input is large causing deformation
Solution Approach 1:
The patent replaces TIG welding with laser beam welding to close the opening portion. The laser beam welding process uses a focused laser beam instead of an arc to melt and join the plug material to the opening, providing superior control over heat input and melting characteristics. This substitution enables achievement of both flat surface finish and precise control of thermal deformation, resolving the contradiction between ease of manufacture and manufacturing precision.
Solution Approach 2:
The patent changes the welding parameters by using laser beam welding with specific power settings, scanning speeds, and focal positions to control the heat input and melting depth. By adjusting these parameters, the process achieves precise control over the welding zone, ensuring flat surface finish while minimizing heat-affected zone and preventing deformation, thus resolving the contradiction between ease of closing and surface quality.
2Ease of manufacture
If TIG welding is used to close the opening portion, then the opening can be sealed, but heat input is large causing deformation of the fabricated object
Solution Approach 1:
The patent replaces TIG welding with laser beam welding to close the opening portion. The laser beam welding process uses a focused laser beam instead of an arc to melt and join the plug material to the opening, providing superior control over heat input and melting characteristics. This substitution enables achievement of both flat surface finish and precise control of thermal deformation, resolving the contradiction between ease of manufacture and manufacturing precision.
Solution Approach 2:
The patent changes the welding parameters by using laser beam welding with specific power settings, scanning speeds, and focal positions to control the heat input and melting depth. By adjusting these parameters, the process achieves precise control over the welding zone, ensuring flat surface finish while minimizing heat-affected zone and preventing deformation, thus resolving the contradiction between ease of closing and surface quality.
3Object-affected harmful factors
If LMD method is used to close the opening portion, then heat input is suppressed, but bottomless opening portions cannot be closed
Solution Approach 1:
The patent replaces LMD method with laser beam welding to close the opening portion. The laser beam welding process provides direct and efficient energy delivery to the welding zone, enabling effective closure of bottomless openings while maintaining low heat input. The focused laser beam can penetrate and weld through deep openings, overcoming the limitation of LMD method while preserving the advantage of reduced heat input.
Solution Approach 2:
The patent changes the welding parameters by using laser beam welding with specific power settings, scanning speeds, and focal positions to control the heat input and melting depth. By adjusting these parameters, the process achieves precise control over the welding zone, ensuring flat surface finish while minimizing heat-affected zone and preventing deformation, thus resolving the contradiction between ease of closing and surface quality.
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 allows for easy closure of the opening portion with improved surface flatness and reduced heat input, ensuring the integrity and material consistency of the fabricated object, even in high-temperature environments.
Implementation Method 1
a three-dimensional object is formed by repeatedly welding and solidifying through irradiating a metal powder layered with an energy beam such as a light beam or an electron beam
Implementation Method 2
irradiating a metal powder layered with an energy beam such as a light beam or an electron beam
Data Source
AI summary
A method of manufacturing a fabricated object includes forming the fabricated object by laminating metal powder, the fabricated object including an opening portion that communicates with a hollow internal space, mounting a plug in the opening portion, and welding the plug mounted in the opening portion to the fabricated object.