Amorphous Alloy Foil 3D Printing Without Crystallization
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Solution Overview
Problem
Existing 3D printing methods for amorphous alloys face limitations in forming large-sized parts with complex shapes and dense structures due to crystallization and residual stress issues, leading to poor surface quality and internal density.
Innovation Solution
A laser 3D printing system using a first laser to cut the internal contour of amorphous alloy foil, followed by selective heating with a second laser to a temperature between the glass transition and initial crystallization temperatures, and rolling with a roller equipped with a resistance heating rod and ultrasonic emitter to achieve interatomic bonding between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If amorphous alloy material is heated to a molten state for 3D printing, then the material can be formed into complex shapes, but crystallization occurs in the part
Solution Approach 1:
The patent changes the temperature parameter control strategy by heating the amorphous alloy foil to a temperature between the glass transition temperature and the initial crystallization temperature, rather than melting it. This parameter change allows the material to become formable while avoiding the crystallization that occurs at higher temperatures
Solution Approach 2:
The patent utilizes the glass transition phase transition of the amorphous alloy material. By heating to the glass transition temperature range, the material transitions from a rigid glassy state to a supercooled liquid state with improved formability, while remaining below the crystallization temperature to maintain the amorphous structure
2Strength
If amorphous alloy foil is heated to a molten state for layer bonding, then interlayer bonding is achieved, but the internal structure becomes less dense
Solution Approach 1:
The patent changes the bonding mechanism from thermal melting to pressure-induced bonding. By applying pressure through a roller at elevated temperatures (between glass transition and crystallization temperatures), the amorphous alloy layers bond through plastic deformation and interdiffusion without melting, preserving density while achieving strong interlayer bonding
Solution Approach 2:
The patent replaces the thermal field (heating to molten state) with a mechanical field (pressure application through roller). This substitution allows bonding to occur through mechanical pressure and plastic deformation rather than melting, maintaining the dense amorphous structure while achieving interlayer bonding
3Volume of stationary object
If high-energy laser beam is used to heat molten powders for selective laser sintering, then large-size parts can be formed, but large residual stress leads to cracking
Solution Approach 1:
The patent changes the temperature parameter from high-energy melting temperatures to lower temperatures between the glass transition and initial crystallization temperatures. This parameter change reduces thermal gradients and residual stress while still enabling large-size part formation through the superplasticity of the amorphous alloy in the supercooled liquid region
Solution Approach 2:
The patent utilizes the superplasticity phase transition of amorphous alloys in the supercooled liquid region. This phase transition provides exceptional formability and reduces residual stress during forming, allowing large-size parts to be formed without cracking while maintaining structural integrity
4Shape
If amorphous alloy powder is used for 3D printing, then complex structures can be formed, but preparation cost is high and utilization rate is low
Solution Approach 1:
The patent uses amorphous alloy foil instead of powder. The foil form factor enables higher material utilization rates with less waste during the 3D printing process, while still allowing complex structures to be formed through layer-by-layer stacking and bonding of the foil material
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 enhances the surface quality and internal density of the amorphous alloy parts by preventing crystallization and releasing residual stress, allowing for the production of large-sized, complex-shaped parts with improved formability and cost-effectiveness compared to traditional powder-based methods.
Implementation Method 1
selective heating with a second laser to a temperature between the glass transition and initial crystallization temperatures
Implementation Method 2
a resistance heating rod and an ultrasonic emitter are provided in the roller
Implementation Method 3
the ultrasonic emitter is used for emitting ultrasonic waves during the rolling process to achieve ultrasonic rolling
Data Source
AI summary
The invention belongs to the field of additive manufacturing of amorphous alloy, and discloses a laser 3D printing forming system of amorphous alloy foil and a forming method thereof. The unnecessary material of the amorphous alloy foil is cut by a first laser and then the remaining portion is selectively scanned and heated by a second laser so that the amorphous alloy is heated to be in a superplastic state in the supercooled liquid region. Then, the amorphous alloy foil is rolled by a preheated roller in combination with the ultrasonic vibration to achieve interatomic bonding between layers of the amorphous alloy foil, and the amorphous alloy foil is then rapidly cooled, so that an amorphous alloy part with a large size, a complicated shape and a porous structure is formed. The invention has overcome the limitation of the size and shape of the amorphous alloy prepared by the traditional amorphous alloy preparation methods, and uses amorphous alloy foil as a raw material, which has lower cost than the traditional 3D printing amorphous powder. In addition, a roller is used to roll the ultra-thin amorphous alloy foil such that the prepared amorphous alloy part has a more compact internal structure.