Anchoring Droplet Deposition for Dissimilar Material Joining

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Solution Overview

Problem

Existing additive manufacturing techniques face challenges in joining dissimilar materials without introducing a heat-affected zone (HAZ) and undesirable phases, and they often require vacuum chambers which limit their applicability.

Innovation Solution

An additive manufacturing system that uses a controller to independently control the composition, formation, and application of metallic anchoring droplets to join different materials, reducing the heat input and avoiding the formation of undesirable phases by applying droplets with specific compositions and heating strategies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to join different materials, then the materials are joined together, but a heat affected zone (HAZ) is formed that affects joint properties

Engineering Contradiction:

Improvejoint strengthVSAvoidheat affected zone

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The welding process is segmented into discrete droplet deposits rather than continuous heat application. Each droplet is individually controlled and deposited, creating localized heating zones that minimize the overall heat affected zone while maintaining joint strength through cumulative bonding.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The process changes the thermal parameters by using controlled, intermittent heating through discrete droplet deposition rather than sustained high heat. This allows precise control of heat input, reducing HAZ formation while achieving adequate bonding strength through controlled thermal cycles.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If direct manufacturing processes are used to build materials, then materials can be built up with electron beam, but vacuum chamber is required which reduces availability

Engineering Contradiction:

Improvematerial building capabilityVSAvoidvacuum chamber requirement

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The process replaces the electron beam mechanism with a mechanical droplet deposition system. Instead of using high-energy electrons to melt and deposit material, the invention uses mechanically controlled droplet ejection and deposition, eliminating the need for vacuum chambers while maintaining additive manufacturing capabilities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The process replaces the vacuum environment with an inert or controlled atmosphere environment. By using gas shielding instead of vacuum, the system maintains material protection from oxidation and contamination while eliminating the complex vacuum chamber infrastructure, thereby increasing versatility and reducing device complexity.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Strength

If incompatible base materials are mixed into a weld, then materials are joined, but undesirable phases or intermetallic structures form

Engineering Contradiction:

Improvematerial jointVSAvoidmaterial phases

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The process applies local quality control by allowing different material compositions in different droplets deposited at different locations. Each droplet can be tailored with specific composition ratios, enabling localized optimization of material properties and preventing unwanted intermetallic formation through controlled spatial distribution of alloying elements.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The process introduces dynamic control over material composition during deposition. The controller can adjust droplet composition in real-time based on location, previous deposits, and desired final properties, allowing adaptive prevention of undesirable phases while maintaining joint integrity through dynamic compositional adjustment.

Inventive Principle:

Principle #15Dynamics

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 enables efficient joining of materials with reduced HAZ, maintaining the properties of the workpieces and allowing for the use of dissimilar materials without the need for vacuum chambers, thereby enhancing the versatility and quality of the joints.

Implementation Method 1

The additive manufacturing tool 18 may utilize one or more types of energy to form and deposit the droplets 20

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

the additive manufacturing tool 18 forms (e.g., prints) the part 12 from one or more anchoring materials 22 by depositing multiple droplets 20

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Implementation Method 3

The controller 30 may control the heating of the droplet 20 and/or the workpiece 14, 16

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS11833623B2Additive manufacturing system for joining and surface overlay

Publication Date: 2023.12.05 ILLINOIS TOOL WORKS INC

AI summary

An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material of the plurality of metallic anchoring materials.