Composite Member Deposition With In-Place Machining
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Solution Overview
Problem
Conventional methods for manufacturing composite members, such as cladding and sintering, face issues like insufficient filling of alloy material at angled portions leading to air bubbles, decreased connection strength, and thermal conductivity, and require separate machining apparatuses for processing.
Innovation Solution
A composite member is manufactured using additive manufacturing with directed energy deposition, allowing for the integration of different materials on a substrate within a machining area of a machine tool capable of subtractive machining, enabling prompt machining and improved thermal conductivity and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cladding or sintering methods are used to manufacture composite members, then material addition is achieved, but insufficient filling at angled portions occurs leading to air bubbles, decreased connection strength, and decreased thermal conductivity
Solution Approach 1:
The patent combines the additive manufacturing process and subtractive machining process into a single integrated machine tool system. The additive manufacturing unit deposits material layer by layer to completely fill angled portions and grooves, while the machining unit subsequently removes excess material and performs precision finishing. This merging eliminates the problem of insufficient filling at angled portions that occurs with conventional separate processes, as the additive process can precisely target and fill complex geometries without the material handling issues of conventional cladding or sintering.
Solution Approach 2:
The patent uses composite materials consisting of a base material (e.g., aluminum alloy) and a cladding material (e.g., copper alloy or nickel-based alloy) with different properties. The additive manufacturing process deposits the cladding material in a controlled manner to completely fill grooves and angled portions, ensuring proper wetting and bonding without air bubbles. This approach creates a metallurgically sound composite structure with improved connection strength and thermal conductivity compared to conventional methods.
2Ease of manufacture
If conventional cladding is performed by a separate apparatus, then material addition is achieved, but the composite member requires relocation to a different machine tool for machining, increasing manufacturing time and complexity
Solution Approach 1:
The patent integrates the additive manufacturing unit and subtractive machining unit into a single machine tool system. The additive manufacturing unit deposits material to form the desired geometry, and the machining unit immediately follows to perform precision machining operations on the same workpiece without relocation. This integrated approach eliminates the time and complexity associated with moving the composite member between separate cladding and machining apparatus, achieving both material addition and precision machining in one continuous process.
Solution Approach 2:
The machine tool system is designed with multi-functionality, capable of performing both additive manufacturing and subtractive machining operations. This universal system can complete the entire manufacturing process from material deposition to final machining within a single apparatus, eliminating the need for separate specialized equipment and reducing manufacturing steps. The system effectively combines the functions of multiple machine tools into one versatile platform.
3Quantity of substance
If sintering is used to manufacture composite members, then material consolidation is achieved, but alloy material powder mixture is insufficiently filled at angled portions leading to air bubbles and decreased thermal conductivity
Solution Approach 1:
The patent replaces the sintering process with an additive manufacturing process that uses directed energy deposition. Instead of relying on powder consolidation through heat and pressure, the additive process melts and deposits material in a controlled manner, ensuring complete filling of angled portions and grooves. This substitution eliminates the air bubble formation issue inherent in sintering, as the molten material naturally flows into and completely fills complex geometries, resulting in denser material with improved thermal conductivity.
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 rapid production of composite members with enhanced thermal conductivity and strength by integrating materials with higher thermal conductivity and strength within the machining process, addressing the limitations of conventional methods.
Implementation Method 1
adding, on a surface of a first member 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
Data Source
AI summary
A composite member is manufactured by a manufacturing method including adding, on a surface of a base member 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 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.