DED Compression Roller Head for Uniform Forge-Like Deposition
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Solution Overview
Problem
Conventional Directed Energy Deposition (DED) apparatuses 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
The system integrates a deposition head and compression rig that apply compressive loads simultaneously during material deposition, using a rotary build table and rollers to apply constant temperature compression, enabling a local forging process within the DED process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If compression and deposition phases are conducted sequentially in conventional DED apparatuses, then the equipment structure can be simplified, but the processing time increases and microstructure uniformity deteriorates
Solution Approach 1:
The patent combines the deposition head and compression rig into a single integrated system that performs both material deposition and compression simultaneously. The deposition head includes both the material delivery nozzle and the compression apparatus with rollers, allowing the two processes to occur in the same spatial location and time period, thereby reducing processing time without requiring separate equipment
2Manufacturing precision
If compression is applied after deposition in conventional DED apparatuses, then the deposition process can be completed first, but the microstructure becomes uneven due to variable temperature and processing time increases
Solution Approach 1:
The patent implements continuous compression action during the entire deposition process. The compression rollers apply force continuously to the deposited material while it is still hot and plastic, maintaining constant temperature and pressure conditions that promote uniform microstructure formation. This eliminates the temperature variations and delays associated with sequential processing
3Strength
If conventional DED apparatuses use separate deposition and compression phases, then the system operation can be simpler, but the inability to apply constant temperature compression prevents forging-like qualities
Solution Approach 1:
The patent merges the deposition and compression functions into a single integrated head assembly. The compression rig with rollers is positioned within the deposition head structure, allowing simultaneous application of compressive force during material deposition. This integration enables constant temperature compression that produces forging-like microstructural qualities while maintaining a unified, easier-to-operate system
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 uniform microstructure, and allows for the production of components with forge-like qualities by applying compressive loads at a consistent temperature during deposition.
Implementation Method 1
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, 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
Data Source
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.