Amorphous Alloy 3D Preform Forging for Large Complex Parts
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Solution Overview
Problem
Current methods for manufacturing amorphous alloy parts face limitations in size and complexity due to crystallization, poor internal structure density, and thermal stress issues, restricting their application in large and complex-shaped components.
Innovation Solution
A cold additive and hot forging combined forming method using micro-jetting and bonding 3D printing to create a pre-forging blank, followed by hot closed-die forging, which allows for the production of large-size and complex-shaped amorphous alloy parts with a completely amorphous structure and high dimensional precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If copper mold casting or water quenching method is used to obtain amorphous alloy, then completely amorphous structure is achieved, but size is limited to maximum 80 mm in diameter
Solution Approach 1:
The part is divided into two stages: first, a pre-forging blank with amorphous structure is created through cold additive manufacturing (segmenting the manufacturing process); second, this blank undergoes hot forging to achieve the final large-size part. This segmentation allows the amorphous structure to be established in a smaller initial form that can then be expanded without crystallization.
Solution Approach 2:
The amorphous structure is preliminarily established in the pre-forging blank through cold additive manufacturing before the hot forging process. This preliminary action ensures that the material starts with the desired amorphous structure, which is then maintained during subsequent heating and forging operations through controlled temperature parameters.
2Ease of manufacture
If thermoplastic forming method is used, then amorphous alloy parts are obtained, but large-sized and complex-shaped parts are difficult to manufacture
Solution Approach 1:
The invention merges cold additive manufacturing (which excels at creating complex shapes) with hot forging (which excels at producing large-sized dense parts). The cold additive step creates the complex pre-forging blank, while the hot forging step transforms it into the final large-size part with improved density and mechanical properties, combining the advantages of both methods.
3Volume of moving object
If powder sintering method is used, then size limitation is broken through, but internal structure is not dense enough and mechanical properties are poor
Solution Approach 1:
The invention changes the temperature parameter during the forming process. Instead of sintering at relatively low temperatures that produce porous structures, the material is heated to high temperatures (above glass transition temperature but below crystallization temperature) during hot forging. This parameter change enables dense internal structure formation while maintaining the amorphous state, achieving both large size and high density.
4Volume of moving object
If welding assembly method is used, then large-sized parts are assembled, but welding thermal stress causes deformation and cracking
Solution Approach 1:
The invention replaces the welding process (which introduces thermal stress and potential cracking) with a hot forging process. The pre-forging blank is heated and then forged under controlled conditions to achieve the final large-size shape. This mechanical substitution eliminates the harmful thermal cycling and stress concentration associated with welding, improving structural integrity while maintaining the capability to produce large parts.
5Volume of moving object
If additive manufacturing method is used, then size limitation is broken through, but crystallization and microcrack problems occur during forming
Solution Approach 1:
The invention introduces a pre-forging blank as an intermediary form. The cold additive manufacturing process creates this intermediate blank with the desired complex geometry, which then serves as the starting material for hot forging. This intermediary step allows the amorphous structure to be established in a controlled manner before the high-temperature forming process, preventing direct crystallization issues that would occur if additive manufacturing attempted to produce the final large part in one step.
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 method breaks size limitations, improves material utilization, reduces thermal defects, and achieves high precision and density, enabling the production of large and complex amorphous alloy parts with superior mechanical properties.
Implementation Method 1
gas generated by gasification or decomposition of the binder at a hot die forging temperature
Implementation Method 2
gas generated by gasification or decomposition of the binder at a hot die forging temperature
Implementation Method 3
hot closed-die forging
Implementation Method 4
exhibit superplasticity in the supercooled liquid region, which enables thermoplastic forming
Data Source
AI summary
The present invention discloses a cold additive and hot forging combined forming method of amorphous alloy parts. The present invention belongs to the field of cold additive manufacturing technology and thermoplastic forming of amorphous alloy, and more particularly relates to a cold additive and hot forging combined forming method of amorphous alloy parts, the method comprising: (1) making amorphous alloy powder into a pre-forging blank by the micro-jetting and bonding 3D printing technology; and (2) placing the pre-forging blank in the step (1) in a closed forging die to perform hot closed-die forging so as to obtain an amorphous alloy part, wherein the contour size and shape of the pre-forging blank are designed according to the contour size and shape of the inner cavity of the closed forging die; and an exhaust hole is provided in the closed forging die such that gas generated by gasification or decomposition of the binder at a hot die forging temperature is discharged through the exhaust hole in the closed forging die. In the present invention, a bulk amorphous alloy part with a large size and a complex shape can be prepared by the cold additive and hot forging combined forming method.