DED Compression Rig With Thermal Feedback for Uniform Microstructure
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Solution Overview
Problem
Current Directed Energy Deposition (DED) systems face challenges in simultaneously conducting material deposition and applying compression, leading to increased processing time and uneven microstructure due to sequential phases, which limits the production of components with forging-like qualities.
Innovation Solution
The integration of a compression rig with temperature and distance sensors into the DED system allows for simultaneous material deposition and compression, using a compression head with rollers to apply a compressive load during deposition, controlled by a controller that adjusts position and load based on real-time temperature and distance data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If compression is applied after material deposition in sequential phases, then the compression equipment can be positioned outside the working volume during deposition, but the total processing time increases as the sum of deposition time and compression time
Solution Approach 1:
The patent merges the deposition and compression phases into a single simultaneous operation by integrating the compression apparatus within the working volume during active deposition. The compression head with rollers applies compression forces to freshly deposited material while the deposition nozzle continues to deposit material, eliminating the sequential waiting time and reducing total processing time.
Solution Approach 2:
The patent introduces a new spatial dimension by positioning the compression head to operate within the working volume during deposition. The compression apparatus uses rollers that contact the deposited material from above, creating a vertical compression dimension that coexists with the horizontal deposition process, allowing both operations to occur simultaneously in different spatial zones.
2Ease of manufacture
If compression is applied to material at varying temperatures, then the compression can be performed on deposited layers, but the microstructure becomes uneven
Solution Approach 1:
The patent implements a feedback control system using temperature sensors to monitor the temperature of deposited material in real-time. The controller receives temperature data and adjusts the compression forces applied by the rollers to maintain optimal compression conditions. This feedback mechanism ensures that compression is applied at appropriate temperatures, preventing microstructure unevenness while enabling continuous compression during deposition.
3Ease of operation
If compression apparatus is positioned outside working volume during deposition, then the deposition phase can proceed without interference, but the compression phase cannot occur simultaneously with deposition
Solution Approach 1:
The patent combines the deposition and compression operations into a single integrated process by positioning the compression head within the working volume. The compression apparatus operates simultaneously with the deposition nozzle, applying compression forces to freshly deposited material while the deposition process continues, thereby increasing productivity without interfering with deposition.
Solution Approach 2:
The patent segments the working volume into distinct operational zones: a deposition zone where the nozzle deposits material, and a compression zone where the compression head applies forces to the deposited material. This spatial segmentation allows both operations to occur simultaneously without interference, maintaining deposition independence while enabling concurrent compression.
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 microstructure, and enables the production of components with forge-like qualities by applying compression at optimal temperatures, thereby improving mechanical properties and reducing defects.
Implementation Method 1
a pair of temperature sensors positioned on opposite sides of the top roller and detecting a temperature of the top surface of the component
Implementation Method 2
a compression head supporting a top roller applying a compressive load onto a top surface of a component
Implementation Method 3
a pair of distance sensors positioned on opposite sides of the top roller and detecting a distance to the top surface of the component
Implementation Method 4
a controller configured to adjust a position of the compression rig and a load applied by the top roller based on at least one of the detected temperatures and distances
Data Source
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AI summary
An additive manufacturing system for forming a component including a compression rig including a compression head supporting a top compression device applying a compressive load onto a top surface of the component, a pair of temperature sensors positioned on opposite sides of the top compression device and detecting a temperature of the top surface of the component, and a pair of distance sensors positioned on opposite sides of the top compression device and detecting a distance to the top surface of the component, and a controller configured to adjust a position of the compression rig and a load applied by the top compression device based on at least one of the detected temperatures and distances.