Amorphous Additive Manufacturing with Ultrasonic Nanocrystal Control
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Solution Overview
Problem
Conventional additive manufacturing methods produce polycrystalline or equiaxed microstructures with defects and inhomogeneity, requiring post-processing that leads to grain growth, compromising yield strength and fatigue resistance.
Innovation Solution
An additive manufacturing system using a pulsed laser and ultrasonic transducers to create an amorphous structure with a high cooling rate and nanocrystal grains, allowing for the formation of an amorphous matrix with controlled vibration during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing methods are used to produce polycrystalline structures, then the manufacturing process is straightforward, but the structure contains defects and inhomogeneity requiring post-processing that causes grain growth and compromises mechanical properties
Solution Approach 1:
The patent applies parameter changes by controlling the cooling rate during additive manufacturing to achieve amorphous structure formation. By maintaining cooling rates above a critical threshold (e.g., >10^5 K/s), the process transforms the microstructure from polycrystalline to amorphous, eliminating defects and inhomogeneity without requiring post-processing interventions.
Solution Approach 2:
The patent utilizes phase transitions by controlling the solidification process to form an amorphous phase instead of a crystalline phase. By managing the cooling rate to prevent nucleation and crystal growth, the material transitions directly from liquid to amorphous solid state, producing a homogeneous microstructure free of grain boundaries and defects.
2Reliability
If post-processing (heat treatment, HIP) is applied to polycrystalline structures, then defects are addressed, but grain growth occurs compromising yield strength and fatigue resistance
Solution Approach 1:
The patent applies preliminary action by forming the amorphous structure directly during the additive manufacturing process itself, rather than creating a polycrystalline structure and then attempting to correct defects through post-processing. The amorphous structure is created in-situ with controlled cooling rates, eliminating the need for subsequent heat treatment or HIP processes that would cause grain growth.
3Strength
If high cooling rates are applied to form amorphous matrix, then ductility and fatigue resistance improve, but brittleness may increase without nanocrystal grain formation
Solution Approach 1:
The patent applies composite materials by creating a hybrid microstructure consisting of nanocrystal grains dispersed within an amorphous matrix. This composite structure combines the advantages of both phases: the amorphous matrix provides high ductility and fatigue resistance, while the nanocrystal grains serve as reinforcement to reduce brittleness and enhance overall mechanical properties.
Solution Approach 2:
The patent applies local quality by creating a heterogeneous microstructure where nanocrystal grains are distributed within the amorphous matrix. Different regions of the material have different local structures - the amorphous phase provides ductility while the nanocrystal regions provide strength and reduce brittleness, achieving optimal mechanical properties through spatial variation in microstructure.
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 system produces a hybrid structure with nanocrystalline grains in an amorphous matrix, enhancing ductility, fatigue resistance, and elastic strain while minimizing brittleness, thereby improving the mechanical properties of the manufactured articles.
Implementation Method 1
The energy applicator can include a laser. The control module can be configured to pulse the laser.
Implementation Method 2
The control module can be configured to control the laser to cause an amorphous matrix formation cooling rate to form an amorphous matrix.
Implementation Method 3
The energy applicator can include one or more acoustic transducers disposed on or in the build platform to provide vibration during additive manufacturing to the article and/or a portion thereof to cause formation of nanocrystal grains in the amorphous matrix.
Data Source
AI summary
An additive manufacturing system configured to additively build an article can include an energy applicator, a build platform, and a powder nozzle configured to eject powder toward the build platform to be acted on by the energy applicator. The system can include a control module configured to control the energy applicator to create an amorphous structure forming at least a portion of the article.