Cavity Structure Assembly Using Vacuum Welding and HIP Bonding
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Solution Overview
Problem
Current methods for manufacturing structures with cavities, such as heat exchangers, face challenges in achieving complex shapes without deformation, displacement, or shift, and often result in poor mechanical strength and high machining costs due to limitations in geometric and dimensional tolerances.
Innovation Solution
A method involving forming recessed areas in a substrate, depositing a plate over the substrate, and performing resistance, electron-beam, or transparent laser welding under vacuum, followed by hot isostatic pressing diffusion welding, which ensures tightness and avoids deformation by creating a uniform weld with minimal residual stresses and reduced machining costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If additive manufacture (3D printing) is used to manufacture components with complex geometric shapes, then complex shapes and good mechanical characteristics are obtained, but dimensional and geometric tolerances are not complied with
Solution Approach 1:
The component is divided into multiple plates that are assembled together to form the final structure. Each plate can be manufactured with precise tolerances using conventional machining, while the overall complex geometry is achieved through the assembly of these segmented plates with cavities formed between them
Solution Approach 2:
The invention changes the manufacturing approach from monolithic additive manufacturing to a segmented assembly process, transforming the problem from achieving complex shapes with poor tolerances to assembling precisely manufactured plates that collectively form the complex geometry
2Shape
If material removal machining is used to form channels, then channels are created in solid elementary parts, but not all desired geometries, sections and lengths can be obtained
Solution Approach 1:
Instead of attempting to machine complex channel geometries from solid blocks, the invention segments the structure into plates with cavities, allowing complex geometries to be formed by the assembly arrangement rather than by removing material from a single solid part
Solution Approach 2:
Rather than removing material to create channels (subtraction), the invention uses material removal to create cavities in plates, then assembles these plates so that the cavities form the desired channel geometries (additive approach to channel formation)
3Adaptability or versatility
If diffusion welding with pre-deformed tubes between grooved plates is used, then tubes with different sections and curvatures are obtained, but only recessed portions with simple geometric shapes can be produced
Solution Approach 1:
The structure is segmented into multiple plates that can be independently manufactured with various cavity geometries, allowing complex recessed portions to be formed by the assembly of these plates rather than being constrained to simple shapes
Solution Approach 2:
The invention moves from forming complex shapes within single tubes to creating complex three-dimensional cavity networks across multiple plates, utilizing the additional dimension of plate stacking and arrangement to achieve geometric complexity
4Strength
If two diffusion welding cycles are used to assemble plates with grooves, then welding by diffusion is achieved, but channels are deformed during the first cycle due to absence of internal pressure
Solution Approach 1:
The plates are pre-assembled with cavities formed before the diffusion welding process, so that the channel geometries are established prior to welding. This preliminary formation of cavities prevents deformation during the welding cycle since the cavities are already in their final configuration
Solution Approach 2:
The invention provides structural support to the cavities during assembly to prevent collapse or deformation before welding occurs, ensuring that the channels maintain their intended geometry throughout the welding process without requiring internal pressure
5Shape
If filler material is inserted into channels to prevent deformation during welding, then channel deformation is avoided, but complete elimination of the filler material is difficult
Solution Approach 1:
The invention extracts the filler material concept entirely by using the plate assembly structure itself to provide support during welding. The plates are designed and assembled to maintain cavity geometry without requiring any filler material to be inserted, eliminating the subsequent removal step
Solution Approach 2:
Instead of using filler material as an intermediary to prevent deformation, the invention uses the plate assembly structure itself as the intermediary, where the relative positioning and mechanical interlocking of plates provide the necessary support during welding without requiring additional filler materials
6Reliability
If laser welding of thin blades over grooves is used to close recessed portions, then tightness is guaranteed, but strict width tolerances (0.1 mm) are required which increases machining costs and complicates the method
Solution Approach 1:
The structure is segmented into plates with cavities formed between them, eliminating the need for thin blades and grooves entirely. This segmentation allows for more relaxed tolerances since the cavity formation does not depend on precise interlocking of thin elements
Solution Approach 2:
Instead of adding thin blades to close grooves (additive approach with tight tolerances), the invention uses material removal to create cavities in plates, inverting the approach to achieve tightness through cavity formation rather than blade insertion and welding
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 enables the production of structures with complex cavity shapes while maintaining mechanical integrity and reducing implementation costs, avoiding deformation and achieving tight seals, even in narrow cavities, with the ability to assemble different materials and maintain high mechanical properties.
Implementation Method 1
carrying out a resistance welding, an electron-beam welding or a transparent laser welding, preferably under vacuum, around the recessed areas, whereby the plate is welded onto the substrate and cavities are formed
Implementation Method 2
carrying out a resistance welding, an electron-beam welding or a transparent laser welding, preferably under vacuum, around the recessed areas, whereby the plate is welded onto the substrate and cavities are formed
Implementation Method 3
carrying out a resistance welding, an electron-beam welding or a transparent laser welding, preferably under vacuum, around the recessed areas, whereby the plate is welded onto the substrate and cavities are formed
Implementation Method 4
carrying out a step of hot isostatic pressing diffusion welding on the obtained assembly
Implementation Method 5
carrying out a step of hot isostatic pressing diffusion welding on the obtained assembly
Data Source
AI summary
A method for manufacturing a structure comprising cavities, the method comprising the following steps: a) forming recessed areas in a first face of a substrate made of a first material, b) depositing a plate made of a second material over the first face of the substrate, so as to cover the recessed areas of the substrate, c) carrying out a resistance welding, an electron-beam welding or a transparent laser welding, preferably under vacuum, around the recessed areas, whereby the plate is welded onto the substrate and cavities are formed, and d) carrying out a step of hot isostatic pressing diffusion welding on the obtained assembly.