Composite Additive Forming With Real-Time Micro-Forging Control
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Solution Overview
Problem
Additive manufacturing methods using the 'melting-solidification' technique struggle to achieve comprehensive performance comparable to forged materials due to coarse, directionally oriented crystals, and the complexity of combining molten deposition with thermomechanical processing makes it difficult to effectively control forging conditions.
Innovation Solution
A composite forming system that integrates additive manufacturing with real-time micro-forging using a movable micro-forging device comprising a first and second forging hammer, which generates controlled deformations in the solidified portions, allowing for precise refinement of the material's internal structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the 'melting-solidification' method is used to achieve metallurgical bonding of metal materials, then parts can be manufactured by surfacing, but the internal microstructure produces very coarse crystals with obvious directionality, making it difficult to achieve comprehensive performance comparable to forged material
Solution Approach 1:
The patent combines additive manufacturing and forging processes into a composite processing system. The additive manufacturing device deposits material layer by layer while the forging device simultaneously applies pressure to the deposited material, merging two processes that were previously separate. This integration allows the system to produce parts with improved mechanical properties by refining the coarse crystalline structure through forging while maintaining the additive manufacturing capability to create complex geometries
Solution Approach 2:
The patent applies thermomechanical processing parameters (temperature, pressure, deformation rate) to the additive manufacturing process. By controlling the forging parameters such as pressure magnitude, temperature range, and deformation speed, the system transforms the microstructure of the deposited material from coarse and directional to finer and more uniform, thereby improving mechanical properties while maintaining manufacturing flexibility
2Strength
If a method of combining molten deposition additive with thermomechanical processing is used to improve mechanical properties, then grain refinement and internal quality improvement can be achieved, but the high complexity of the process and equipment makes it difficult to effectively control forging conditions including temperature and other parameters
Solution Approach 1:
The patent integrates the additive manufacturing device and forging device into a single composite processing system with a unified control architecture. By merging the control systems of both processes, the patent simplifies the overall control complexity while maintaining the ability to apply thermomechanical processing parameters. The integrated system allows simultaneous control of material deposition and forging operations through coordinated motion control and parameter management
Solution Approach 2:
The patent introduces a control device as an intermediary that coordinates between the additive manufacturing device and forging device. This control intermediary manages the complex interactions between the two processes by synchronizing their operations, managing parameter transitions, and coordinating the timing of material deposition with forging application, thereby simplifying the overall system complexity
3Productivity
If rapid solidification and cooling rate are used in the melting process, then material deposition can be achieved quickly, but the forging condition which includes temperature and other parameters cannot be effectively controlled, thus affecting the scope of application of the materials as well as the effect of forging
Solution Approach 1:
The patent applies forging to the deposited material in real-time while the additive manufacturing process is still ongoing or immediately after deposition. This preliminary action of forging while the material is still hot from deposition allows the system to take advantage of the high temperature state without requiring separate heating steps, thereby maintaining both high productivity and effective temperature control for forging operations
Solution Approach 2:
The patent maintains continuous operation of both additive manufacturing and forging processes without interruption. The forging device continuously applies pressure to the deposited material as it is being formed, ensuring that the useful action of both processes continues without pause. This continuity allows the system to maintain high deposition rates while simultaneously achieving effective temperature control through the ongoing thermomechanical processing
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 enhances the mechanical properties of the materials by enabling precise control over forging conditions, reducing internal defects, and improving the quality of the final product, making it suitable for high-temperature alloys like nickel-based and cobalt-based alloys.
Implementation Method 1
uses a high-energy beam such as a laser beam, an electron beam or an arc beam as a heat source to melt the synchronously fed metal material
Implementation Method 2
melt the synchronously fed metal material, such as metal powder, metal wire, and so on, which are stacked in layers, whereby parts are manufactured by surfacing, and the internal microstructure of the obtained parts is a solidified structure
Implementation Method 3
the first forging hammer is configured to impact the solidified portion to generate a first deformation, and the second forging hammer is configured to impact the solidified portion to generate a second deformation
Implementation Method 4
impacting the solidified portion with the first forging hammer to generate a first deformation
Data Source
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AI summary
The present invention relates to an additive manufacturing system and its methods. The system includes a material conveyor, an energy source, and a micro-forging device. The material conveyor is configured to convey material. The energy source is configured to direct an energy beam toward the material, the energy beam fuses at least a portion of the material to form a solidified portion. The micro-forging device is movable along with the material conveyor for forging the solidified portion, wherein the micro-forging device comprises a first forging hammer and a second forging hammer, the first forging hammer is configured to impact the solidified portion to generate a first deformation, and the second forging hammer is configured to impact the solidified portion to generate a second deformation greater than the first deformation.