Amorphous Additive Manufacturing with Pulsed Laser Cooling
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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, which affects 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 controlled cooling rate and vibration, forming an amorphous matrix with nanocrystal grains, which minimizes brittleness and enhances fatigue resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
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 reduces yield strength
Solution Approach 1:
The patent applies parameter changes by controlling the cooling rate during additive manufacturing to achieve amorphous structure formation. Specifically, the cooling rate is maintained between 10^5 to 10^10 K/s, which prevents crystallization and creates an amorphous matrix, thereby eliminating grain boundaries and associated defects without requiring post-processing
Solution Approach 2:
The patent utilizes phase transitions by controlling the solidification process to form an amorphous phase rather than a crystalline phase. The rapid cooling rate causes the material to transition directly from liquid to amorphous solid state, bypassing the crystalline phase entirely, which eliminates grain structure and improves yield strength
2Reliability
If post-processing heat treatment is applied to polycrystalline structures, then defects can be addressed, but grain growth occurs that reduces 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 that would cause grain growth
3Strength
If amorphous structure is formed through rapid cooling, then yield strength and fatigue resistance improve, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies periodic action through pulsed laser heating during additive manufacturing. The laser delivers periodic thermal energy input, creating controlled thermal cycles that facilitate rapid heating and cooling. This periodic energy input enables amorphous structure formation while using standard additive manufacturing equipment, avoiding excessive complexity
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, improving yield strength, fatigue resistance, and elastic strain while maintaining ductility, reducing the need for post-processing and enhancing material performance.
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
Figure 1~2
Figure 3
AI summary
An additive manufacturing system configured to additively build an article can include an energy applicator (101), a build platform (103), and a powder nozzle (107) configured to eject powder toward the build platform to be acted on by the energy applicator. The system can include a control module (109) configured to control the energy applicator to create an amorphous structure forming at least a portion of the article.