Arcuate Base Plate for Additive Layer Manufacturing
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Solution Overview
Problem
Additive layer manufacturing (ALM) methods for producing arcuate components face challenges in predicting and controlling mechanical properties due to axial grain orientation, which leads to cracking, and require significant support structures that consume material and energy.
Innovation Solution
A base plate movable along an arcuate path allows for better support of fused material and optimizes grain orientation in the circumferential direction, reducing the need for support structures and enhancing mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If axial build direction is used to manufacture arcuate components, then the component can be grown layer by layer, but axial grain orientation arises which increases the likelihood of cracking
Solution Approach 1:
The patent inverts the conventional axial build direction by implementing a circumferential build direction. The build plate rotates to deposit layers in the circumferential direction rather than the axial direction, fundamentally changing the grain orientation from axial to circumferential, thereby eliminating the crack-prone columnar grain boundaries while maintaining manufacturability
Solution Approach 2:
The patent changes the build direction parameter from axial to circumferential. By modifying this fundamental process parameter, the grain orientation is transformed to align with the circumferential direction, which matches the stress distribution in arcuate components and significantly improves crack resistance while preserving the layer-by-layer manufacturing capability
2Reliability
If circumferential build direction is used, then grain orientation may match stress distribution, but the part-formed component becomes inherently unstable requiring support structures
Solution Approach 1:
The patent employs support structures that extend radially outward from the circumferential edge of the component to counterbalance the weight of the overhanging fused material. These support structures provide the necessary mechanical stability during the build process, allowing the circumferential build direction to be used without compromising component stability
3Stability of the object's composition
If support structures are used to stabilize the component, then component stability is improved, but significant portion of powdered material and energy beam time is consumed
Solution Approach 1:
The patent designs the support structures to be temporary and removable after the component is complete. The support structures are discarded after serving their stabilizing function, and the radial edges of the component are trimmed to remove excess material. This approach allows the use of support structures during manufacturing while minimizing their impact on the final product and overall material efficiency
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 minimizes the need for support structures and aligns grain orientation with stress/work load, improving the mechanical properties of arcuate components by ensuring better material support and controlled grain structure during ALM.
Implementation Method 1
selectively consolidating or fusing the powder using an energy beam such as a laser or an electron beam
Implementation Method 2
moving the base plate away from the energy beam source to a vertically lower second position; wherein moving the base plate from the first position to the second position comprises moving the base plate along an arcuate path
Data Source
AI summary
The present disclosure relates to a system for forming an arcuate component by additive layer manufacturing (ALM). The system comprises a base plate for receiving a layer of powdered material and having opposing inner and outer transverse edges and an energy beam source for generating an energy beam for fusing a portion of the powdered material. The base plate is moveable away from the energy beam source from a first position to a vertically lower second position along an arcuate path such that the outer transverse edge traces an outer arc having a greater radius than an inner arc traced by the inner transverse edge. The present disclosure also relates to a base plate apparatus for use in ALM that is movable along an arcuate path and an ALM method using the base plate apparatus/system.