AM Metal Preforms for Single-Die Forging of Complex Parts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for forging metal products are inefficient in achieving desired mechanical properties and surface quality, particularly with materials like titanium alloys, due to limitations in deformation processes and substrate integration in additive manufacturing.
Innovation Solution
The method involves using additive manufacturing to produce metal shaped-preforms, which are then forged using a single die forging step with controlled temperature differentials and subsequent annealing to achieve improved mechanical properties and surface finish, allowing for the production of complex geometries and multi-material components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional multi-step forging processes are used, then complex geometries can be achieved, but manufacturing time and process complexity increase significantly
Solution Approach 1:
The patent applies preliminary action by creating a preform through additive manufacturing that is specifically designed to require only a single subsequent forging step. The preform geometry is optimized in advance to enable near-net-shape forging, eliminating the need for multiple intermediate forging operations and significantly reducing total manufacturing time while maintaining complex geometry capability
2Shape
If additive manufacturing is used to produce preforms, then complex geometries and multi-material components are enabled, but surface roughness and porosity increase
Solution Approach 1:
The patent applies parameter changes by optimizing additive manufacturing parameters (layer thickness, build orientation, infill patterns) and forging parameters (temperature, pressure, strain rate) to transform the surface quality and internal structure. The controlled forging process densifies the porous AM structure and improves surface finish, converting the inherent drawbacks of additive manufacturing into acceptable or improved final product quality
3Strength
If multiple forging dies are used for successive deformation steps, then mechanical properties are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies merging by consolidating multiple forging operations into a single die design that performs all necessary deformation steps in one forging cycle. The single die incorporates features that enable sequential deformation zones, allowing complex shape changes and mechanical property enhancement to be achieved without requiring multiple separate dies, thereby reducing device complexity and manufacturing cost
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 results in final forged products with enhanced mechanical properties, reduced porosity, improved surface roughness, and cost-effective production, suitable for aerospace and other high-performance applications.
Implementation Method 1
using additive manufacturing to produce a metal shaped-preform
Implementation Method 2
heating the metal shaped-preform to a stock temperature
Implementation Method 3
contacting the metal shaped-preform with a forging die... deforming the metal shaped-preform via the forging die
Implementation Method 4
subsequent annealing to achieve improved mechanical properties
Data Source
AI summary
The present disclosure is directed towards different embodiments of additively manufacturing and smoothing an AM preform to configure an AM preform for downstream processing (working, forging, and the like).