DED Compression Roller Rig for Simultaneous Deposition and Forging
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Solution Overview
Problem
Conventional Directed Energy Deposition (DED) systems apply compression and deposition phases sequentially, leading to increased processing time, uneven microstructure due to variable temperature, and inability to produce components with forging-like qualities.
Innovation Solution
A DED system that simultaneously applies compression forces using a rotary build table, deposition assembly, and compression rig with inside, outside, and top rollers, allowing for continuous deposition and compression, enabling local forging processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If compression and deposition phases are conducted sequentially in conventional DED systems, then the equipment structure is simpler, but the processing time increases and productivity decreases
Solution Approach 1:
The patent combines the deposition assembly and compression rig into a single integrated system where the deposition head and compression rollers share the same robotic arm and build table. This merging allows simultaneous deposition and compression operations, resolving the contradiction by enabling parallel processing while maintaining coordinated control through a unified system architecture.
Solution Approach 2:
The system enables continuous useful action by allowing the deposition head to deposit material while compression rollers simultaneously compress the freshly deposited layer. This continuous parallel operation eliminates idle time between phases, maintaining productive action throughout the entire process cycle and significantly improving throughput.
2Temperature
If compression is applied after deposition in conventional systems, then the temperature of deposited material varies, but achieving consistent temperature requires additional control mechanisms
Solution Approach 1:
The compression operation is performed immediately on the freshly deposited material while it is still hot and pliable. This preliminary action captures the material in its most receptive state, ensuring consistent temperature and microstructure without requiring complex temperature control systems. The timing of compression is optimized to occur during the deposition phase itself.
3Strength
If sequential compression and deposition is used, then the system is easier to operate, but the ability to produce forging-like qualities is lost
Solution Approach 1:
The integration of deposition and compression functions into a single coordinated system enables the production of forging-like qualities through simultaneous operation. The merged system maintains precise control over both processes, applying compression forces to freshly deposited material to create refined microstructures and enhanced mechanical properties while preserving ease of operation through unified control.
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 reduces processing time, ensures consistent temperature for compression, and enables the production of components with forge-like qualities and improved mechanical properties.
Implementation Method 1
DED apparatuses use a focused energy source, such as a laser or electron beam, to melt the feedstock material
Implementation Method 2
a compression rig including a compression head supporting an inside roller, an outside roller opposing the inside roller, and a top roller, the inside roller applying a compressive load onto an interior side surface of the component
Data Source
Figure 1
Figure 2
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AI summary
An additive manufacturing system for producing a component includes a deposition assembly having a deposition head through which melted feedstock material is deposited, and a compression rig comprising a compression head supporting an inside roller, an outside roller opposing the inside roller, and a top roller, the inside roller applying a compressive load onto an interior side surface of the component, the outside roller applying a compressive load onto an exterior side surface of the component, and the top roller applying a compressive load onto a top surface of the component.