Composite Member Manufacturing via Directed Energy Deposition
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Solution Overview
Problem
Conventional methods for manufacturing composite members, such as cladding and sintering, face issues like air bubbles at angled portions leading to decreased connection strength and thermal conductivity, and require separate machining apparatuses for processing.
Innovation Solution
A method integrating additive manufacturing using a 5-axis machine tool with directed energy deposition to create composite members by layering metals, allowing for simultaneous machining and cladding within the same apparatus, enhancing connection strength and thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cladding or sintering methods are used to manufacture composite members, then the manufacturing process can be completed, but air bubbles form at angled portions leading to decreased connection strength and thermal conductivity
Solution Approach 1:
The patent replaces conventional mechanical cladding or sintering processes with additive manufacturing technology. This substitution eliminates the air bubble formation issue that plagues traditional methods, particularly at angled portions, while maintaining manufacturing feasibility. The additive process builds material layer-by-layer without the harmful voids created by melting and solidification in conventional methods.
Solution Approach 2:
The patent changes the fundamental manufacturing parameters from subtractive or consolidation-based methods to additive deposition. By controlling the deposition process parameters (layer thickness, deposition rate, thermal cycle), the method achieves complete filling of angled portions without air bubbles, thereby improving both connection strength and thermal conductivity while maintaining ease of manufacture.
2Ease of manufacture
If conventional cladding methods are used, then material can be added to the substrate, but separate machining apparatuses are required for processing the composite member
Solution Approach 1:
The patent merges the additive manufacturing function with the machining function into a single integrated apparatus. The composite member is manufactured and processed in one continuous operation within the same machine tool, eliminating the need for separate cladding equipment and machining equipment. This integration reduces device complexity while maintaining full material addition and processing capabilities.
Solution Approach 2:
The patent creates a multi-functional machine tool that can both add material through additive manufacturing and perform subtractive machining operations. This universal apparatus handles the entire composite member manufacturing workflow, from material deposition to final machining, thereby reducing the total number of apparatuses required while preserving both material addition and processing capabilities.
3Reliability
If additive manufacturing is used to create composite members, then thermal conductivity and strength can be improved, but the process time may increase compared to conventional methods
Solution Approach 1:
The patent performs preliminary actions by optimizing the additive manufacturing process parameters before actual production. The process is designed to build structures with optimal thermal pathways and material distribution from the beginning, eliminating the need for extensive post-processing. This preliminary optimization ensures high thermal conductivity and strength are achieved during the building process itself, not as a result of lengthy subsequent treatments.
Solution Approach 2:
The patent maintains continuous useful action by integrating the additive manufacturing process with immediate machining operations in a seamless workflow. The machine tool transitions continuously between deposition and machining modes without removing the workpiece, eliminating idle time and maintaining high productivity. This continuous operation achieves superior thermal conductivity and strength without significant increase in total manufacturing time.
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
Enables the rapid production of composite members with improved thermal conductivity and strength by layering metals within the same machining apparatus, addressing the limitations of traditional methods.
Implementation Method 1
additive manufacturing using a 5-axis machine tool with directed energy deposition to create composite members by layering metals
Implementation Method 2
cladding layer formed by melting and cladding copper alloy powders
Implementation Method 3
irradiating a laser to build up the cladding layer
Data Source
Figure 1
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Figure 4~5
AI summary
A composite member is manufactured by a manufacturing method including the step of adding, on a surface of a base member (110) composed of a first material, a second material different from the first material, using additive manufacturing employing directed energy deposition as an additive manufacturing process. The manufacturing method is performed by placing the base member (110) in a machining area of a machine tool configured to perform subtractive machining. Accordingly, a composite member can be obtained that is manufactured through additive manufacturing and that is in a state in which the composite member can be promptly machined.